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Contents

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Business Management ..........................................3 Lean Methods & Implementation ......................15 Productivity Improvement ..................................22 Organizational Culture ......................................28 Lean Leadership..................................................36 Lean Metrics & Finance ......................................45 Lean Office..........................................................48 Product Development ........................................51 Value Stream Mapping ......................................55 Six Sigma............................................................56 Supply Chain Management................................61

Find the information and resources you need.

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www.ProductivityPress.com • Featured Lean Books includes the newest publications and essential classics, as well as a selection of books that will start you on your Lean journey.

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Business Management

The Organizational Alignment Handbook

The Organizational Master Plan Handbook

A Catalyst for Performance Acceleration

A Catalyst for Performance Planning and Results

H James Harrington and Frank Voehl

H. James Harrington and Frank Voehl

Harrington Institute, Los Gatos, California, USA

Harrington Institute, Los Gatos, California, USA

Examining top-down, bottom-up, and core planning and execution processes, The Organizational Alignment Handbook provides a systematic approach for establishing the infrastructure needed to support a successful transformation and make your strategic plan a reality.

Bridging the gap between macro and micro approaches with a single unified theory, the book provides the understanding needed to assess the effectiveness of your organization’s current management system. It explains how to identify potential projects, introduce new practices, plan for resource allocation, and define and recommend decision governance.

Identifying the capability constraints you must resolve in order for your company to thrive in an increasingly competitive business environment, the book explains: • How the organizational master plan fits into alignment activities • How strategic planning process and outcomes can be made part of the performance plan for individuals • How to use controllable factors as the foundation for your master plan • How to develop a set of vision statements that defines how your organization will function in the future The management skills your organization currently possesses might be effective in today’s environment, but are they the skills needed to meet strategic objectives in the future? This book outlines a step-by-step approach for achieving organization-wide alignment of processes, applications, and systems, and to ensure acceptance of the results by all stakeholders. It includes examples of organizations implementing the strategies discussed as well as a review of the activities you need to follow to minimize the time it takes to reach your objectives.

Catalog no. K13579, November 2011, 282 pp.

ISBN: 978-1-4398-7732-6, $55.95 / £35.99 Also available as an eBook

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“Harrington and Voehl present the most comprehensive and effective approach to optimizing an organization’s performance developed to date. It is must reading for those organizations seeking to prove maximum value to all stakeholders.”

—Tang Xiaofen, President of the Shanghai Association for Quality

“Compulsory reading for all leaders looking to maximize efficiency and effectiveness while navigating business in this risky global economy.”

—Acn. Shan Ruprai President APQO, National Chairman Australian Organisation for Quality

Written for organizational leaders, planners, facilitators, and consultants, this book defines how the four different planning activities used to manage and improve an organization should be merged to maximize effectiveness. Stating that the four plans for organization improvement are the business plan, strategic business plan, strategic improvement plan, and operating plan, it defines each and explains how to link them together to reduce cost and cycle times.

• Discusses all the plans that should go on within an organization • Provides a new approach to preparing a Strategic Improvement Plan • Defines the purpose of each minor plan • Includes a visual roadmap of the Organizational Master plan process

Selected Contents: Overview of the Problem. What’s in an Effective Planning Process? Organization’s Master Plan.

Change Management as Part of the Organization’s Master Plan. Trend Analysis. The Business Planning Process. The Strategic Business Planning Process.

Strategic Improvement Plan. Developing the Strategic Plan. The Annual Operating Plan.

Organization’s Master Plan Summary.

Catalog no. K13684, February 2012, 275 pp.

ISBN: 978-1-4398-7877-4, $52.95 / £33.99 Also available as an eBook

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Business Management

Performance Acceleration Management (PAM) Rapid Improvement to Your Key Performance Drivers H. James Harrington Harrington Institute, Los Gatos, California, USA

The first book in the Little Big Book Series, Performance Acceleration Management (PAM): Rapid Improvement to Your Key Performance Drivers, explains how to accelerate the rate of change and improvement in your organization to exceed your customers’ expectations. It introduces the PAM approach to accelerated performance improvement and explains how to use it to bring about significant change to your organization’s long-term performance. Delving into more than 50 years of experience helping organizations implement improvement approaches, H. James Harrington highlights key opportunities to add value to your organization.

• Introduces the performance acceleration management (PAM) approach to accelerated performance improvement • Explains how to develop a separate vision statement for each of the key performance drivers (KPDs) • Describes how to define desired behavioral patterns and performance goals • Specifies how to prepare individual transformation plans for the KPD vision statements • Demonstrates how to implement a combined PAM plan • Details a method for continuous review of your improvement process • Defines key terms and abbreviations and lists more than 1,400 different performance improvement tools

Selected Contents: Performance Acceleration Management: Its Theory and Practice. Phase I: Conducting an Improvement Requirements Assessment. Phase II: Developing Vision Statements. Phase III: Defining Desired Behavioral Patterns and Performance Goals. Phase IV: Developing Individual KPD Transformation Plans. Phase V: Developing A Five-Year Combined PAM Plan. Phase VI: Implementing the Combined PAM Plan. Phase VII: Continuously Improving. Appendices: Definition and Abbreviations. List of over 1,400 Different Performance Improvement Tools and Methodologies.

Tools/Methodologies Interaction between KPDs.

Closing the Communication Gap An Effective Method for Achieving Desired Results H. James Harrington and Robert Lewis Closing the Communication Gap can help readers improve communication by closing the gap between what the communicator means and what the listener actually understands. It supplies a complete overview of the various elements and dimensions of effective communication needed to stop talking and start communicating.

Defining and discussing both the formal and the informal communication systems within an organization, the book demonstrates the importance of good communication and details the four types of poor-quality communication. It explains how to create a climate of communication in your organization and describes how this climate encourages the development of quality relationships.

• Examines the importance of good communication • Defines the four types of poor-quality communication • Explains how to create a climate of communication • Describes how a climate of communication encourages the development of quality relationships After reading this book, you will understand how to be a better listener, how to use social media in marketing, how to deal with difficult people, and helpful tips for public speaking. You will gain valuable insights on how to talk to your employees, how to talk to your boss, and the best ways to communicate with a corporation.

This book can be read for personal growth or it can be used by a company to teach employees the importance of quality communication. Quality assurance departments will find this book useful in lowering errors and waste in the workplace. The book is also suitable as a communication textbook or supplemental text at the introductory university level.

Catalog no. K16662, October 2013, 316 pp.

Soft Cover ISBN: 978-1-4665-7488-5, $29.95 / £18.99

Catalog no. K16607, March 2013, 220 pp., Soft Cover ISBN: 978-1-4665-7257-7, $29.95 / £18.99

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Business Management

Production and Operations Management Systems

Upgrading Leadership's Crystal Ball Five Reasons Why Forecasting Must Replace Predicting and How to Make the Strategic Change in Business and Public Policy

Sushil Gupta Florida International University, Miami, USA

Martin Starr Rollins College, Winter Park, Florida, USA

Illustrating how operations relate to the rest of the organization, Production and Operations Management Systems provides an understanding of the production and operations management (P/OM) functions as well as the processes of goods and service producers. The modular character of the text permits many different journeys through the materials. If you like to start with supply chain management (Chapter 9) and then move on to inventory management (Chapter 5) and then quality management (Chapter 8), you can do so in that order.

However, if your focus is product line stability and quick response time to competition, you may prefer to begin with project management (Chapter 7) to reflect the continuous project mode required for fast redesign rapid response. An accompanying website offers slides, lectures, Excel worksheets, and solutions to short and extended problem sets.

The project management component of P/OM is no longer an auxiliary aspect of the field. The entire system has to be viewed and understood. The book helps students develop a sense of managerial competence in making decisions in the design, planning, operation, and control of manufacturing, production, and operations systems through examples and case studies. The text uses analytical techniques when necessary to develop critical thinking and to sharpen decision-making skills.

Selected Contents: Workload Assessment. Long Term Planning. Medium Term Planning. Short Term Planning (Scheduling).

Planning for Materials (Inventory Models). Supply Chains and Distribution Planning. Quality Management. New Product Development. Project Management.

Catalog no. K14666, February 2014, 520 pp.

ISBN: 978-1-4665-0733-3, $89.95 / £57.99 Also available as an eBook

Jeffrey C. Bauer Independent Health Futurist and Medical Economist, Chicago, Illinois, USA

“Jeff Bauer’s new book positively crackles with energy and brio, whether he’s busting a myth or sharing an anecdote about WWII meteorology. Like any truly learned teacher, his message is simple and accessible: predictions give us the illusion of precision and trap us in the duality of right and (mostly) wrong. A forecast, by contrast, illuminates a garden of likely outcomes; it stirs our creativity and poises us for action.”

—Tim Ogilvie, CEO, Peer Insight and Co-Author of Designing for Growth

This book offers a practical alternative to the everyday predictive models that have failed to prepare decisionmakers for today's economic problems. Rather than telling readers how to prepare for the future, it offers readers tools to evaluate and influence their own futures.

The text describes key concepts concisely and clearly, including practical examples. The concepts discussed in the chapters can help business executives avoid problems from the past as they look into the future.

• Describes why predicting is inappropriate for today’s dynamic systems • Addresses persistent problems with predictive models, assumptions, and data • Explains how forecasting incorporates uncertainty and unprecedented change • Provides ways to enhance chances for success through forecast-based strategies • Examines the promises and limitations of big data • Includes a foreword by Dr. Stan Gryskiewicz, author of Positive Turbulence

Selected Contents: Introduction. The Big Difference between Predicting and Forecasting. Five Reasons to Stop Making Predictions. Fast-Tracking the Transition from Predicting to Forecasting.

Catalog no. K15302, October 2013, 168 pp.

Soft Cover ISBN: 978-1-4665-5403-0, $29.95 / £19.99 Also available as an eBook

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Business Management

Vanishing Boundaries How Integrating Manufacturing and Services Creates Customer Value, Second Edition Richard E. Crandall Appalachian State University, Boone, North Carolina, USA

William R. Crandall University of North Carolina, Pembroke, USA

Vanishing Boundaries: How Integrating Manufacturing and Services Creates Customer Value, Second Edition addresses the unprecedented array of new conditions that today’s business managers must face. The book is a revision of the authors’ previous book, New Methods of Competing in the Global Marketplace, Critical Success Factors from Service and Manufacturing.

The concepts underpinning the first edition continue to be relevant today and, in this revised edition, are complemented with coverage of additional emerging issues in today’s business environment. The basic theme of the book is captured in its title and illustrated with the addition of case studies of some of today’s most prominent companies.

Navigating Strategic Decisions The Power of Sound Analysis and Forecasting John E. Triantis Long Range Planning Associates, Vero Beach, Florida, USA

Based on four decades of experience and research, Navigating Strategic Decisions: The Power of Sound Analysis and Forecasting explains how to improve the decision-making process in your organization through the use of better long-term forecasts and decision support. Filled with time-tested methodologies and models, it provides you with the tools to establish the organization, processes, methods, and techniques required for analyzing and forecasting strategic decisions.

Describing how to foster the conditions required for forecasts to materialize, this book will help you rank project valuations and select higher value creation projects. It also teaches you how to: • Assess the commercial feasibility of large projects • Apply sanity checks to forecasts and assess their resource implications

New in the Second Edition:

• Benchmark best-in-class strategic forecasting organizations, processes, and practices

• The emerging relationship between risk management and supply management

• Identify project risks and manage project uncertainty

• Risk management, and its corollary, crisis management

• Analyze forecasting models and scenarios to determine controllable levers

• Trends in outsourcing, such as near-sourcing and in-sourcing

• Pinpoint factors needed to ensure that forecasted future states materialize as expected

• Health care improvement programs to reduce cost and improve quality

This book provides you with the benefit of the author’s decades of hands-on experience. In this book, John Triantis shares valuable insights on strategic planning, new product development, portfolio management, and business development groups.

Describing how to provide world-class support to your corporate, market, and other planning functions, the book provides you with the tools to consistently make improved decisions that are based on hard data, balanced evaluations, well-considered scenarios, and sound forecasts.

• Sustainability—alternative energy infrastructure and the triple bottom line • Integration of supply chain services to align goods, information and funds flows • Advances in information technology, such as cloud computing and videoconferencing This second edition creates greater awareness of the benefits that businesses can gain by sharing techniques and methodologies across the manufacturing/services boundary. The book emphasizes that successful change management requires a holistic focus on three levels of an organization—its technology, infrastructure, and organizational culture.

Catalog no. K20271, June 2013, 435 pp.

ISBN: 978-1-4665-8598-0, $99.95 / £63.99 Also available as an eBook

Catalog no. K14593, October 2013, 540 pp.

ISBN: 978-1-4665-0590-2, $89.95 / £57.99 Also available as an eBook

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Business Management

Chance or Choice

From Business Strategy to Information Technology Roadmap

Unlocking Innovation Success Greg McLaughlin Global Targeting, Inc., Fort Lauderdale, Florida, USA

A Practical Guide for Executives and Board Members

Vinny Caraballo Global Targeting, Hawthorn Woods, Illinois, USA

Supplying practical guidance for integrating innovation throughout the organization, this book introduces the authors’ proprietary ENOVALE methodology. ENOVALE is a blueprint that provides leaders and managers of any organization with a strategic framework to initiate and maintain innovation and achieve a sustainable competitive advantage.

What makes this book different is that it originates from decades of experience, cutting-edge research, and empirical evidence. The results come from the authors’ work on Project Impact, an ongoing multiyear global study to measure attitudes, opinions, and disposition of different cultures towards innovation.

Expanding on the current definition of innovation, the book: • Spells out a detailed "how-to" approach for those responsible for innovation leadership • Outlines practical solutions and time-tested strategies • Emphasizes the role of the individual as the ultimate innovator • Presents concepts that are applicable across a range of industries, including the services industry Rather than relegating innovation to the R&D and engineering functions, the book extends the ENOVALE framework into all functions of your organization. It also details a project strategy useful for any type of innovation to help you lead your teams in leveraging the innovative capabilities valued by your customers and users. Throughout the book, the authors outline the tools and concepts you will need to move your organization from simply surviving to thriving in today’s brutally competitive global environment.

Catalog no. K18903, March 2013, 219 pp.

Soft Cover ISBN: 978-1-4665-8186-9, $59.95 / £38.99 Also available as an eBook

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Tiffany Pham, David K. Pham, Andrew Pham Agile Enterprise Consulting, LLC, Plano, Texas, USA

“This book gives a simple, systematic approach to technology design and business strategy—a must read to understand how to compete in the everchanging global landscape. ... From Business Strategy to Information Technology Roadmap presents a simplified approach to moving your enterprise toward success and developing a longterm sustainable strategy and IT foundation.”

—Stephanie Bartz, Director of Strategic Planning, United Healthcare

This book lays out a practical, how-to approach to identifying business strategies and creating value-driven technology roadmaps in your organization. It uses numerous examples, illustrations, and case studies to show you how to solve the real-world problems that business executives and technology leaders face on a day-to-day basis.

Filled with actionable advice you can use immediately, the authors introduce Agile and the Lean mindset in a manner that the people in your business and technology departments can easily understand. Ideal for executives in both the commercial and nonprofit sectors, it includes two case studies: one about a commercial family business that thrived to become a multi-million-dollar company and the other about a nonprofit association based in New York City that fights against child illiteracy.

Selected Contents: Introduction to Business Strategy. Introduction to Lean, Lean and Agile Organization, and Lean and Agile IT. From Business Strategy to IT Roadmap: An Introduction to Enterprise Architecture. From Business Strategy to an Agile and Lean IT Roadmap: the Formulation Process. From IT Roadmap Formulation to Execution. Case Studies.

Catalog no. K19070, May 2013, 298 pp.

ISBN: 978-1-4665-8502-7, $49.95 / £31.99 Also available as an eBook

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Business Management

ENOVALE How to Unlock Sustained Innovation Project Success Greg McLaughlin Inthesis, Inc., Boca Raton, Florida, USA

Vinny Caraballo Global Targeting, Hawthorn Woods, Illinois, USA

Explaining how to achieve sustained innovation success in today’s increasingly competitive global environment, ENOVALE: How to Unlock Sustained Innovation Project Success provides a validated strategy for implementing innovation projects following the ENOVALE™ methodology: envision the need, nominate, objectify, validate, align and adapt, link, and execute.

The authors’ first book, Chance or Choice: Unlocking Innovation Success, introduced a proven management process, using the ENOVALE methodology, for identifying innovation opportunities through validated outcomes. This book takes the outcome and provides a method—from project initiation to completion.

• Goes beyond the typical innovation book to outline specific solutions and strategies • Includes templates, flow charts, tools, and strategies for each "means" of innovation • Provides business examples of the philosophy, strategic elements, and success criteria that readers can easily relate to The text begins by explaining what strategy means in terms of innovation and how it can be transformative for products, processes, and services. After an overview of innovation, the book discusses a series of strategies for each of the three means of innovation.

These strategies outline a systematic process you can use to initiate and conduct your own innovation projects.

The book includes numerous business examples that illustrate the authors’ philosophy, strategic elements, and success criteria. After reading this book you will gain a solid understanding of five time-proven implementation strategies that can be applied to any type of innovation project.

Catalog no. K20545, October 2013, 203 pp.

Soft Cover ISBN: 978-1-4665-9208-7, $69.95 / £44.99 Also available as an eBook

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Four-Cornered Leadership A Framework for Making Decisions John Roland Schultz W. Edwards Deming once stated that the job of management is not supervision but leadership. He also concluded that capable leaders were those who understood and applied the system of profound knowledge. Four-Cornered Leadership: A Framework for Making Decisions examines the system of profound knowledge and identifies the competencies that set the stage for its successful application.

Illustrating the relationship between leaders and followers, it analyzes each of the four pillars that support Deming's system, in relation to prevailing management and organizational theory. It describes a set of competencies based on these core principles that convey very different assumptions about people and organizations.

The book supplies you with a new way to view leadership that is based on learning and continual modification in response to prevailing conditions.

Highlighting the connection between the four elements and an individual’s ability to lead, it presents methods that are applicable in any organizational setting—including government, industry, and education.

The book examines the complexity of human nature and relates it to group and organizational dynamics.

Filled with examples, case studies, and tables, this is the ideal guide for leaders trying to adopt the principles of quality management and continuous improvement.

Selected Contents: Leadership Defined. Understand the Importance of System Interdependencies. Understand Why People Behave as They Do. Understand How People Learn, Develop, and Improve. Understand the Variability of Work. Give Meaning, Purpose, and Direction to the Job at Hand. Manage the Dynamics, Interdependencies, and Interaction. Appendix.

Catalog no. K20585, August 2013, 277 pp.

ISBN: 978-1-4665-9289-6, $59.95 / £38.99 Also available as an eBook

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Business Management

Change or Die

Superior Customer Value

The Business Process Improvement Manual

Strategies for Winning and Retaining Customers, Third Edition

Maxine Attong Guardian General Group, Trinidad

Terrence Metz

Art Weinstein

Morgan Madison & Company, Oak Brook, Illinois, USA

Nova Southeastern University, Fort Lauderdale, Florida, USA

Leadership success depends on clarifying and simplifying complex problems while maintaining a positive outlook. Change or Die - The Business Process Improvement Manual provides you with the tools to do so. Packed with more than 70 pages of workshop tools, agendas, and activities that detail each of the six stages of the business process improvement (BPI) method, it presents a BPI method that promotes the use of facilitator-led workshops to help you and your team make better decisions.

Developed from empirical research and bolstered by the results of client experience from hundreds of hours of facilitated workshops and BPI activity, Change or Die employs the authors' ENGAGE methodology. To ensure your team achieves its deliverables, the authors walk you through each BPI method. In each chapter you will find: • Objectives and deliverables clearly identified • Real-world examples from companies the authors have worked with—presented using a global manufacturer as an example • Activities, questionnaires, and examples • A self-assessment tool to help you measure progress, identify gaps in team performance, and determine team readiness for the next stage This resource-rich book includes a CD with supplemental activities, challenges, facilitated workshops, templates, tables, and questionnaires—tools designed to ease each participant’s path to project success.

Selected Contents: Case Study: URHere Co. Vision and Goals. Change Management. Stakeholder Analysis. Core Process.

Business Process Improvement. Facilitation and Business Process Improvement Methodology. The Case for Business Process Improvement. Tools for Business Process Improvement. Process Selection.

Process Characteristics. Workflow Diagrams.

Workflow Characteristics. Dreams of the Process.

Process Measurements. Strengths and Weaknesses.

Business Process Improvement Planning. ...

Catalog no. K14908, July 2012, 378 pp., Soft Cover ISBN: 978-1-4665-1251-1, $52.95 / £33.99 Also available as an eBook

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"Art Weinstein's latest edition tells you what you must do to create value in your current business environment. A recognized marketing expert, Weinstein not only makes clear the constructs that weave everything together, but he does it in his normal easy-to-understand style. ... a must-read for anyone expecting to successfully compete in their marketplace."

— Dr. RJ Trasorras, President of the Trasorras Intelligence Group, Tampa, Florida

This third edition of a bestseller covers best practices, organizational responsiveness, market orientation, and strategic planning issues that lead to profitable and world-class customer service. This revised edition addresses current trends in value-adding business practice, from understanding how to drive a market and find new ventures to the rise in customer importance of the online arena, new business models, and metrics for customer loyalty and retention. In addition to updated information throughout the text, it also includes new chapters on social media networking and customer value metrics.

Selected Contents: Customer Value—The Building Blocks. Customers Want Exceptional Value! Be Customer Driven and Market Driving. Process Management: Best Practices.

Designing a Successful Customer Strategy. Building a Winning Business Model and Value Proposition.

Service and Quality: The Core Offering. Price and Image: The Communicators. Excelling in the Marketspace. e-Commerce: Opportunities in Marketspace. Integrated Marketing Communications and Social Media. Retaining Customers: Analysis and Strategy. Creating Value through Relationship Marketing. Customer Loyalty and Retention.

Customer Value Metrics. Case Studies. Enterprise Rent-a-Car. FedEx Corporation. The Grateful Dead.

Harrah’s Entertainment, Inc. Publix Super Markets, Inc. State Pride Industrial Laundry.

Catalog no. K12829, February 2012, 319 pp.

ISBN: 978-1-4398-6128-8, $73.95 / £46.99 Also available as an eBook

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Business Management

BusinessDriven IT-Wide Agile (Scrum) and Kanban (Lean) Implementation An Action Guide for Business and IT Leaders Andrew Thu Pham

Driving Strategy to Execution Using Lean Six Sigma A Framework for Creating High Performance Organizations Gerhard Plenert and Tom Cluley

Agile Enterprise Consulting, LLC, Plano, Texas, USA

MainStream GS, LLC, Carmichael, California, USA

David Khoi Pham

This book is not only about understanding business strategy development; it also provides the tools for strategy execution. Offering a current perspective on the importance of developing an integrated strategy for change, the text presents proven implementation tools, in the tradition of Lean and Six Sigma, needed to navigate, design, and execute the strategic plan.

Demonstrating how a well-developed strategy generates excitement within an organization, the authors present insights on implementation tools from a goal setting, building measures, balanced scorecard, and aligning actions perspective.

Spectacle Inc., Providence, Rhode Island, USA

“… the authors provide an excellent overview of both Agile and Kanban practice and help us understand that a one-size-fits-all IT improvement effort is likely doomed to fail. … On top of a very logical seven-step process for IT-wide software capability improvement, this book also includes comprehensive advice, plans, tools, and practical case studies. By reading the book, you will be well equipped to determine what’s best for your IT organization. I am glad to have read it and now have it in my library.”

—Adam Warner, IT Management, Software Delivery Education Service Center, Richardson, Texas

This book explains how to successfully deploy Agile and Kanban on a large scale in order to increase IT delivery capabilities. It factors in change, communication, a sense of urgency, clear and measurable goals, political realities, and infrastructure needs, all of which are critical ingredients for success. Through real-world examples, the authors explain how IT-wide Agile and Kanban can be implemented to the entire enterprise and IT department. The text also includes many templates for use as an on-the-job guide for business and IT leaders and their teams.

• Presents tools for successful implementation of strategy for change • Contains a complete presentation of models and metrics that work • Emphasizes full integration of vision and deployment, bridging the gap between plan and execution to achieving success • Includes private and public sector case studies that demonstrate success from a real-world, competitive, global perspective

Selected Contents:

Features: • Provides practical guidance on how to implement Agile and Kanban in software project management and development to the entire IT department • Includes four case studies along with many templates for use as an on-the-job guides for business and IT leaders and their teams • Contains actionable information that can be used right away in IT departments of any size Catalog no. K15472, August 2012, 196 pp.

Soft Cover ISBN: 978-1-4665-5748-2, $52.95 / £33.99 Also available as an eBook

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• Provides a full overview of strategic planning principles

Organizational Framework. Current and Future Organizational Trends. Role of Strategy in Organizing Change. Strategic Models. The Strategic Process.

Organization Performance Model. Direction and Orientation of the Organization. Strategy Alignment and Deployment / Strategy Execution.

Organizational Performance Measures. An Integrated Strategic Model. Executing the Strategy. Visioning / Scenario Modeling. Vision / Mission / Customer Identification / Priorities / End State / Goals. Priority Based Strategies/ Metrics that Measure / Tasks.

Governance / Performance Reviews / Cascading / Communication. Executing using Lean / Six Sigma.

Repeating the Strategic Cycle. World Class Strategy Status. Defining and Establishing World Class Status.

Catalog no. K13015, April 2012, 247 pp.

ISBN: 978-1-4398-6713-6, $62.95 / £40.99 Also available as an eBook

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Business Management

Performance Evaluation of Industrial Systems

Utilizing the 3Ms of Process Improvement A Step-by-Step Guide to Better Outcomes Leading to Performance Excellence

Discrete Event Simulation in Using Excel/VBA, Second Edition

Richard Morrow

David Elizandro Tennessee Tech University, Cookeville, USA

Healthcare Performance Partners, Nashville, Tennessee, USA

Hamdy Taha

“As an international expert in quality and safety, Utilizing the 3Ms of Process Improvement is my go-to guide for practical applications in process improvement. This is a must read for all professionals looking to create sustainable processes and improve outcomes.”

University of Arkansas, Fayetteville, USA

Discussing fundamental modeling tools, queuing theory, and discrete event simulation for evaluating production systems, this book presents a development environment for discrete event simulation in a language easy enough to use but flexible enough to facilitate modeling complex systems. Incorporating the use of discrete simulation to statistically analyze a system and render the most efficient time sequences, designs, upgrades, and operations, this new edition develops new visualization graphics for DEEDS software, includes improvements in the optimization of the simulation algorithms, and adds a chapter on queuing models.

Features: • Uses Excel to facilitate model development and the presentation of complex results with parallel sophistication and a relatively easier learning curve • Employs Visual Basic for Application (VBA) class definitions to manage the four network nodes efficiently • Makes discrete simulation accessible with Excel/VBA • Includes a CD-ROM program with user feedback for improved installation and troubleshooting instructions

—David Jaimovich, MD, President of Quality Resources International

Leading change in the right direction and sustaining change is extremely difficult without relevant measures and management of those measures. Providing a leadership and management guide to achieving objectives, this book details how to use the 3Ms (Measure, Manage to Measure, Make-it-Easy) of change leadership. It includes case studies from the aviation and manufacturing industries as well as forms to facilitate implementation. The author describes a culture change method based on changing behaviors.

• Discusses change in performance improvement • Details healthcare applications of the 3Ms • Includes forms and templates to make it easy for the reader to apply the 3Ms • Provides a leadership and management guide to achieving objectives • Describes a culture change method based on changing behaviors

Selected Contents:

Simulation Fundamentals. Simulation Modeling.

Probability and Statistics In Simulation. Elements of Discrete Simulation. Gathering Statistical Observations in Simulation. Overview of Deeds.

Network Representation. ExcelNBA and Design Environment for Discrete Event Simulation. VBA. User Interface. Modeling Procedures. Simulation Output.

Analysis of Simulation Results. Model Visualization.

Modeling Special Effects. Advanced Routing Techniques. Applications. ...

Overview of Process Improvement and the 3Ms. Change Leadership. Resistance to Change and Process Improvement. Process Improvement Methodologies. Roadmap for Process Improvement.

Chartering the Process Improvement Work.

Stakeholder Analysis. Finding the Root Causes, Improving, and Controlling. Utilizing the 3Ms: Measure, Manage to the Measure, and Make It Easier. What to Measure. Measure Risk to Achieve High Reliability. Measurement as a System. How to Share and Communicate Measurements. 3Ms: Manage to the Measure. 3Ms: Make It Easier. High Reliability.

Catalog no. K13267, April 2012, 503 pp.

ISBN: 978-1-4398-7134-8, $135.95 / £86.00 Also available as an eBook

Catalog no. K14239, June 2012, 322 pp., Soft Cover ISBN: 978-1-4398-9560-3, $62.95 / £40.99 Also available as an eBook

Selected Contents:

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Business Management

Managing Country Risk

Out of the Present Crisis

A Practitioner’s Guide to Effective Cross-Border Risk Analysis

Rediscovering Improvement in the New Economy

Daniel Wagner

The Center for Excellence in Operations, Inc., Bedford, New Hampshire, USA

Country Risk Solutions, Norwalk, Connecticut, USA

“The first book that combines easily understood text, insightful analysis, and effective strategies to minimize the risks inherent in cross-border business transactions. I consider this book a must read for anyone charged with managing country risk.”

—Mark T. Williams, Executive-in-Resident/Master Lecturer, Boston University School of Management

Explaining how to identify and manage the many risks associated with conducting business abroad, this book provides the real-world insight needed to anticipate the impact of change on business operations. It presents case studies and practical examples that demonstrate how these concepts apply to every day operations. Considering the effect of perception on investment decisions, it describes how to put a country risk assessment into practice and explains how to create a framework, select the right tools, and map out a country risk analysis methodology.

• Describes how to put a country risk assessment into practice • Considers the impact of perception on investment decisions • Explains how to create a framework, select the right tools, and map out a country risk analysis methodology • Includes practical examples and case studies • Written by an industry expert with more than two decades of experience

Selected Contents: Country Risk in Perspective. Foundations of Country Risk Management. Assessing Country Risk. Country Risk Assessment in Practice. Political Risk Insurance.

Tales from the Battle Zone. The Importance of Understanding China and Its Place in the World.

Shifting Pendulums, Pressing Concerns, and the State of the World. Bibliography.

Catalog no. K14372, February 2012, 308 pp.

ISBN: 978-1-4665-0047-1, $104.95 / £66.99 Also available as an eBook

Terence T. Burton

“This book provides the inspiration and direction for rediscovering improvement while integrating technology as a major enabler to strategic and operating success. Follow the step-by-step advice in this book and your organization will put the word continuous back into continuous improvement.”

—Phil Pegg, Vice President, Business Management Office, North America Marketing, SAP

Providing quick and easy reference to the fundamentals of getting continuous improvement right within the complexities of the new economy, this book explains exactly what it takes to implement Lean Six Sigma and other strategic improvement initiatives with lasting success. It supplies a rediscovered but practical view of improvement for readers across a wide range of industries—including CEOs and their executive teams, middle managers, physicians, nurses, claims managers, politicians, union leadership, and anyone else with the desire to implement enduring improvement.

• Provides a proven roadmap for success with continuous and sustainable improvement • Offers quick reference on the fundamentals of achieving continuous improvement • Includes examples of million dollar improvement opportunities for public and private corporations and service organizations • Features chapters dedicated to continuous improvement in healthcare and federal, state, and local governments

Selected Contents: The Seeds of Continuous Improvement.

Infrastructure Overview. Leadership: Building A HighPerformance Culture. Setting a Renewed Course of Improvement. Deployment Planning for Rapid and Sustainable Results. Execution and Sustainability.

Transforming Culture through Internalization. The Role of Technology in Strategic Improvement. The Multimillion-Dollar List of Improvement Opportunities. Strategic Improvement in Hospitals and Government.

Catalog no. K14522, May 2012, 301 pp.

ISBN: 978-1-4665-0442-4, $31.95 / £20.99 Also available as an eBook

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Business Management

Keeping Your Business in the U.S.A.

Lean Innovation Understanding What's Next in Today's Economy

Profit Globally While Operating Locally Tim Hutzel

Barry L. Cross

Mainstream Management, Cedar Rapids, Iowa, USA

Queen's University, Kingston, Ontario, Canada

In Lean Innovation: Understanding What's Next in Today's Economy, Barry Cross explores how to use Lean to free up resources from within the organization to support and “fund” innovation and inspire a culture of creativity. Easy-to-read and humorous, Cross’s stories resonate and his tactics are very applicable. He demonstrates that you likely have the people needed to drive innovation.

Based on Cross’s 25 years of experience, and filled with stories and anecdotes from a number of industries, the book presents a different look at innovation and how to recognize opportunities for moving past merely talking about innovation to action and making it a priority. The author examines roadblocks and how to use enablers like Lean to facilitate and focus the approach on driving the focus forward.

Features: • Explains how to eliminate waste within the company and offer clarity in the presentation of value to customers • Offers simple, straight-forward, actionable takeaways and solutions • Explores how to apply Lean concepts to free up resources and fund innovation • Balances organizational culture between execution and creativity

Paul Piechota University of Dayton, Ohio, USA

“The authors debunk the notion that American companies have to outsource manufacturing to remain competitive in the global marketplace. The three case studies provide evidence that with the right leadership, companies can increase quality, market share, and profits without shipping jobs overseas. A must read for executives and managers wrestling with outsourcing decisions.”

—Timothy C. Krehbiel, Farmer School of Business, Miami University, Ohio

Keeping Your Business in the U.S.A. shows American enterprises how to survive and prosper while keeping their manufacturing base within the United States. It tells the stories of three manufacturing companies that have been able to achieve overwhelming success while keeping jobs in the U.S. Using case studies, the book illustrates each company’s story from the day it started. It examines the successes, failures, lessons learned, and methods used by each company to achieve and sustain success.

• Debunks the myth that U.S. manufacturers can't compete with cheap labor countries • Features real data and concrete steps instead of theoretical explanations

• Includes stories and anecdotes from industry that expand on key concepts

• Presents proven principles and practices to help keep your business operations in the U.S. and explains how to customize those practices to your business

Selected Contents:

Selected Contents:

Preparing the Organization for Innovation. The Need for Innovation. What’s Lean Got To Do With It? Driving Innovation. The Innovation Framework.

Innovation Culture. Generating Ideas. Refining Ideas.

Spreading the Ideas for Adoption. Embedding Innovation for Long-Term Growth. Back to Culture.

Stories of Successful Companies. Company Story 1— Small Manufacturer. Company Story 2—Medium Manufacturer. Company Story 3—Large Manufacturer. Recipes For Success. Selecting the Companies for Our Stories. How We Developed the Recipes. Identifying the Seven Common Recipes.

About the Ingredients. Personal Self-Assessment.

Personal Insights and Thoughts. Next Steps.

Catalog no. K15036, December 2012, 219 pp.

ISBN: 978-1-4665-1525-3, $52.95 / £33.99 Also available as an eBook

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Catalog no. K10400, September 2011, 135 pp.

ISBN: 978-1-4398-0778-1, $43.95 / £28.99

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Business Management

Applied Concept Mapping

Escape the Improvement Trap

Capturing, Analyzing, and Organizing Knowledge

Five Ingredients Missing in Most Improvement Recipes

Edited by

Michael Bremer and Brian McKibben

Brian Moon, Robert R. Hoffman, Joseph Novak, and Alberto Canas The expanding application of Concept Mapping includes its role in knowledge elicitation, institutional memory preservation, and ideation. With the advent of the CmapTools knowledge modeling software kit, Concept Mapping is being applied with increased frequency and success to address a variety of problems in the workplace.

Supported by business application case studies, Applied Concept Mapping: Capturing, Analyzing, and Organizing Knowledge offers an accessible introduction to the theory, methods, and application of Concept Mapping in business and government.

The case studies illustrate applications across a range of industries—including engineering, product development, defense, and healthcare.

The authors provide access to a free download of CmapTools, courtesy of the Institute for Human and Machine Cognition, to enable readers to create and share their own Concept Maps. Offering examples from the United States, Canada, Australia, Spain, Brazil, Scotland, and the Netherlands, they highlight a global perspective of this dynamic tool. The text facilitates the fundamental understanding needed to harness the power of Concept Mapping to develop viable solutions to a virtually unlimited number of realworld problems.

• Introduces the value of Concept Mapping to the business community • Covers applications in a variety of industries, including consumer products, engineering/ product development, defense, and healthcare • Includes access to free download of CmapTools software, to enable readers to create and share their own Concept Maps

Selected Contents: Introduction. Concept Mapping for Knowledge Preservation and Transfer. Concept Mapping for Analysis. Concept Mapping for Design and Ideation.

Deploying Concept Mapping in Organizations.

“... a must-read book for all senior executives seeking to change the culture of their organization and drive it to a level 4 or 5 on the Improvement Maturity Curve. We have all suffered from the difficulty of sustaining improvement ... this book lays out the sustaining process in a simple, common sense way that is easy to read.”

—Basem Hishmeh, Chairman, Sigma-Netics, Inc.

“… Escape the Improvement Trap is a practical, how-to guide to performance improvement for senior management. ... easy to read, explains concepts simply, and provides concrete examples.”

—Sirreadalot.org, December 2010

Despite performance improvement initiatives such as Lean, Six Sigma, and supply-chain management, only a handful of companies actually break out of the pack to transform their enterprise. This problem is not unique to today's improvement methodologies; the same issues existed when organizations first adopted TQM, re-engineering, and other popular improvement methodologies.

Providing helpful methods and metrics for effecting true change, this book highlights how to avoid common improvement traps that inhibit many organizations from rising above the rest.

• Presents an improvement maturity model that describes five basic levels of improvement effectiveness • Explains why Level 3 organizations (companies improving at a pace slightly better than the average) get trapped in that stage • Discusses the ingredients typically holding back Level 3 companies from advancing to Level 4 organizations (Companies beginning to transform) • Explains how to avoid the Level 3 Tools Trap Catalog no. K10932, September 2010, 319 pp.

Soft Cover ISBN: 978-1-4398-1796-4, $57.95 / £36.99 Also available as an eBook

Catalog no. K11403, February 2011, 380 pp.

ISBN: 978-1-4398-2860-1, $65.95 / £42.99

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Lean Methods & Implementation

Creating a Lean and Green Business System

The Innovative Lean Enterprise Using the Principles of Lean to Create and Deliver Innovation to Customers

Techniques for Improving Profits and Sustainability Keivan Zokaei, Hunter Lovins, Andy Wood, and Peter Hines

Anthony Sgroi, Jr. Director of R&D, Unger Enterprises

Numerous studies from the likes of the Economist Intelligence Unit, Harvard, MIT Sloan, and others indicate that organizations that commit to goals of zero waste, zero harmful emissions, and zero use of nonrenewable resources clearly outperform their competition.

“Tony Sgroi has developed an innovative approach to making marketing decisions on a Lean basis.

Everything is done to create value and eliminate waste. He includes an interesting visual system for assessing and communicating the quality of any prospective marketing opportunity.”

This book is packed with case studies and examples that illustrate how leading firms use Lean and green as simultaneous sources of inspiration in various sectors of industry—from automotive and retail to textile and brewing. Take Toyota as an example, the holy grail of economic efficiency for decades. This book, shows that Toyota tops the green chart too, describing Toyota’s notion of Monozukuri: sustainable manufacturing.

—Philip Kotler, S. Kellogg School of Management, Northwestern University

Creating a Lean and Green Business System: Techniques for Improving Profits and Sustainability offers opportunities for innovation that can simultaneously reduce dependence on natural resources and enhance global prosperity. It explores less understood aspects of Lean and green—discussing their evolution independently as well as the opportunities that exist in their integration, highlighting the importance of a cultural shift across the whole company.

Selected Contents: Why Lean and Green? Need for Green Business Practices in an Economic Downturn. Lean and Green: Principles and Strategies. Creating A Lean and Green Business System. Lean and Green Business Process Management. Lean and Green Business Leadership. Lean and Green Strategy Deployment. Lean and Green Supply Chain Collaboration. The Way Forward. Lean and Green Growth: An East Anglian Model.

Catalog no. K16523, May 2013, 253 pp., Soft Cover ISBN: 978-1-4665-7112-9, $29.95 / £19.99 Also available as an eBook

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“Tony Sgroi has given you the secret to succeed. By implementing each step Tony Sgroi has outlined in each chapter, you will create a building block for success. I really wish I had this book when I was developing my 35 companies.”

—Ken Varga, author of How To Get Customers To Call, Buy & Beg for More!

This book explains how to use Lean principles to drive innovation and strategic portfolio planning. It outlines simple yet powerful visual Lean tools that can enhance idea generation and product development.

It discusses customer value in the form of the benefits customers desire and walks readers through the processes of using Lean techniques to effectively evaluate the quality of any prospective marketing opportunity. Filled with examples that readers can easily relate to, it includes examples from a variety of industries including healthcare.

Selected Contents: Visual Strategy. Understanding the Current State.

Opportunity Identification. Idea Generation.

Delivering Profitable Innovation to Targeted Customers. Barriers to Imitation. Applications of Graphical Strategy Tools. Ranking Offerings. The Strategy Transformation Process. Strategy Transformation Example. Alignment and Position Statements.

Catalog no. K21339, August 2013, 315 pp.

ISBN: 978-1-4822-0390-5, $59.95 / £38.99

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15

Lean Methods & Implementation

Implementing Standardized Work

Implementing Standardized Work

Writing Standardized Work Forms

Process Improvement

Alain Patchong

This book, the third in a series dedicated to Standardized Work, focuses on process improvement.

Implementing Standardized Work: Process Improvement begins by explaining why standardization and process improvement are two sides of the same coin—both needing each other to achieve true sustainability.

The first book in The OneDay Expert series detailed the initial steps that a young, high-potential plant manager in an industrial group, took to assess his plant’s situation through measurement of operators’ performance. The second book in the series, Implementing Standardized Work: Writing Standardized Work Forms, focuses on the next step of this assessment—writing Standardized Work forms to help identify variability and waste.

This book uses numerous examples, charts, and drawings to illustrate the interaction between operator, machine, and material. Besides process analysis, the book discusses process analysis charts, Standardized Work charts, Standardized Work combination tables, and operator work instructions. It also: • Summarizes key points after each step to reinforce understanding • Contains many illustrations to help make application easy • Includes access to additional materials on the book’s website After reading this book you will understand how to use Standardized Work forms as the starting point to establishing a safe and ergonomic work place that delivers quality products in an efficient manner.

Selected Contents: Introduction. Training Day. "We Already Have Standards!". On Which Tasks Can Standardized Work Forms Be Written? Collecting Data. Introducing the Four Standardized Work Documents. Getting Ready.

Writing the Forms. Shop Floor Application.

Takeaway.

Alain Patchong

Describing how to use Standardized Work forms to identify easy opportunities for process improvement, the book includes simple tools and forms that readers can use to achieve quick improvements to boost morale and sustain motivation during the work ahead. Maintaining a focus on process improvement, it covers essential knowledge using a compelling story format.

Following in the tradition of other books in The OneDay Expert series, this book tells the story of Thomas, a young, high-potential plant manager in an industrial group. In this installment, Thomas opens a new front line in his quest to turn around the plant's inefficiency.

He tries a new type of relationship with the labor union based on mutual trust and constructive partnership, while negotiating a competitiveness plan.

Readers will also see how he continues to push for the implementation of Standardized Work.

Covering the essential methods and tools of process improvement in a manner that is easy to understand, this book can help you become familiar with the key concepts of Standardized Work and process improvement in just one day.

Catalog no. K16002, April 2014, 101 pp., Soft Cover ISBN: 978-1-4665-6358-2, $19.95 / £13.99

Catalog no. K16000, May 2013, 111 pp., Soft Cover ISBN: 978-1-4665-6354-4, $19.95 / £13.99

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Lean Methods & Implementation

Implementing Standardized Work

Popular Manufacturing Myths

Measuring Operators’ Performance

Eliminating Widely Held Beliefs That Reduce Competitiveness

Alain Patchong This book, the first in The One-Day Expert series dedicated to Standardized Work, is about operator performance measurement.

Implementing Standardized Work: Measuring Operators’ Performance explains how to measure the performance of operators quickly and simply without sacrificing accuracy.

Detailing how to identify the most efficient operators and how to monitor their improvement over time, it describes a method that has been applied with success for years in the automotive industry. Grounded in one of the basic laws of factory physics—mastery of variability—this method can be automated very easily and thereby requires no labor consumption.

In this episode of The One-Day Expert, Thomas, a plant director in an industrial group, is reassigned to another plant that is losing money. Morale in the plant is very low and the staff is pessimistic about the plant’s future and is distrustful of senior management.

Thomas’ urgent mission is to turn the plant around.

Previous plant managers have tried several initiatives with limited results.

To face these challenges, Thomas has decided to use Standardized Work deployment to achieve quick and visible results while rebuilding a real team. This book recounts these initial steps of the Standardized Work deployment. It explains how to find and apply the best operational method that will lead to cost reductions, better product quality, and increased operator safety. Additional steps are detailed in other books in the series.

Catalog no. K15992, October 2012, 93 pp.

Soft Cover ISBN: 978-1-4665-6328-5, $20.95 / £14.99

Douglas B. Relyea Quality Principle Associates, Norwich, Connecticut, USA

Addressing the beliefs and attitudes that can be detrimental to your organization’s competitiveness, Popular Manufacturing Myths: Eliminating Widely Held Beliefs That Reduce Competitiveness offers time-tested insight into the most common myths encountered in manufacturing environments. It classifies these myths into management myths, shop floor myths, and if appropriate, shared management and shop floor myths.

Explaining the reasons why these deeply ingrained beliefs exist, the book outlines remedies that can help to quickly dispel them within your organization. It presents case studies that examine these myths and includes numerous real-world examples that outline simple, yet effective, solutions. Some of the myths dispelled in this book include: • Increasing line speed always decreases quality and creates more scrap • Reducing the cost of raw materials will decrease the cost of manufacturing • Increased inspection will boost quality • If it is successful in R&D, it will be successful in production • Process problems can only be solved by changing one process parameter at a time Covering the basics of data collection tools, techniques, and analysis, the text offers simple methods to structure your data to assist in communicating clear and logical conclusions across the organization. The author keeps the arithmetic and statistics to a minimum, so readers only require a basic understanding of averaging and normal variation. However, for those who wish to understand a little bit more about a particular concept, technique, tool, or procedure, the book includes an addendum chapter with more detailed explanations and sample calculations.

Catalog no. K16289, April 2013, 135 pp.

ISBN: 978-1-4665-6660-6, $39.95 / £25.99

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Lean Methods & Implementation

The Basics of Achieving Professional Certification Enhancing Your Credentials Willis H. Thomas Associate Director of Learning Management, Pfizer/Wyeth Research, Montvale, New Jersey, USA

This easy-to-use guide can help anyone looking to achieve professional certification make informed decisions about the many options available. It can also help avoid the pitfalls of making the wrong choice as a result of being incorrectly informed. Examining the range of professional certifications offered by associations and organizations, it explains how to select the right professional certification and outlines best practices for completing the certification process.

The book includes a CD that represents more than a year of development between resources in the U.S. and Europe. Packed with tools, it supplies permanent access to a suite of helpful training and development software, including: • Library management system to track training material, books, and related items (created in MS Access) • Learning management system to ensure training compliance (created in MS Access) • A number of project management resources, including a comprehensive exam preparation program • Royalty free multimedia resources to add pizzazz to your e-learning programs • Forms, templates, and checklists to support training administration • Software to make training and certification more interactive and enjoyable Winner of a Cleland Publication Award, Willis H. Thomas, PhD, PMP, CPT, not only outlines the requirements for obtaining professional certification, but also provides a framework for training and development that supports the range of professional certifications.

The book includes helpful test-taking tips for oral and written exams and also describes how to find supporting resources for study group participation.

The Modern Theory of the Toyota Production System A Systems Inquiry of the World’s Most Emulated and Profitable Management System Phillip Marksberry “Dr. Marksberry looks at TPS in the context of organizational behavior, social sciences, management science, and engineering sciences. He presents new insights into how the elements of TPS work together as a system across an organization. Both scholars and practitioners of TPS and Lean manufacturing will find this book to be thought provoking and revealing about how successful TPS operates.”

— Professor Larry Holloway, University of Kentucky

Designed to aid in the implementation of Lean manufacturing, The Modern Theory of the Toyota Production System explains that your organization already has what it takes to succeed with TPS and what’s probably missing is balance.

Bridging the gap between implementation and theory, this text is the first of its kind to use systems theory to study how the pieces of the Toyota Production System (TPS) work together to achieve this muchneeded balance. Lean practitioners will learn how to use system theory to improve overall decision making when applying Lean or Toyota-like management systems.

Explaining that the glue that holds the pieces of TPS together is just as important as the pieces themselves, the book provides you with invaluable guidance in the implementation of Lean manufacturing from a management perspective. It outlines a blueprint to help you develop a clear understanding of how the pieces of TPS need to come together so you can achieve something greater than what’s possible with the individual pieces.

Catalog no. K15434, November 2012, 451 pp.

ISBN: 978-1-4665-5674-4, $73.95 / £46.99

Catalog no. K15324, November 2013, 216 pp.

Soft Cover ISBN: 978-1-4665-5456-6, $19.95 / £12.99 Also available as an eBook

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Lean Methods & Implementation

Green Products

Lean Sustainability

Perspectives on Innovation and Adoption

Creating Safe, Enduring, and Profitable Operations

Edited by

Joao Neiva de Figueiredo

Dennis Averill

Saint Joseph’s University, Philadelphia, Pennsylvania, USA

Unilever, Bel Air, Maryland, USA

Mauro F Guillen The Wharton School, University of Pennsylvania, USA

“This book is an excellent starting point in the analysis of production possibilities compatible with the requirements of sustainability and environmental friendliness. The analysis sector by sector makes it an essential reference for any approach to a topic that will surely dominate the business and academic agendas in the coming years.”

—Emilio Ontiveros, Chairman of AFI and Board Member of Iberdrola Renovables

Sharing successful examples of sustainable products from around the world, this book supplies in-depth analysis of key factors that affect the adoption of sustainable products. It examines case studies of green products from a business perspective and considers both technological and public-policy concerns. The text examines success stories in green production including: the transition from oil dependency to sustainability in Denmark, the revival of battery-powered electric vehicles in Japan, and sustainable tourism in the Galapagos Islands.

Winner of a Shingo Research and Professional Publication Award!

A how-to manual on the proper integration of safety and environmental sustainability with Lean implementations, this book provides a proven recipe for achieving safety and sustainability excellence. This book is the result of the author’s two decades of experience implementing Lean; Safety, Health, and Environmental (SHE); and sustainability processes in the chemical, food, and consumer products industries. It unveils valuable lessons learned and littleknown tips for eliminating waste and increasing process efficiency—while reducing safety incidents and the overall impact on the environment.

The text illustrates how to use the SHE Pillar as a gateway to continuous improvement, regardless of the improvement methodology you use. Bolstered with proven methodologies and real-world advice, it introduces novel approaches for achieving safety and sustainability excellence, including:

• Shares successful examples of sustainable products from around the world

• Autonomous Safety—supplying employees with the knowledge, skills, and motivation to work safely

• Supplies in-depth analysis of key factors that affect the adoption of sustainable products

• Triple Zero—the achievement of zero accidents, zero environmental incidents, and zero losses

• Examines case studies of green products from a business perspective—considering both technological and public policy concerns

• Green Value Stream Mapping—the application of Value Stream Mapping to environmental and sustainability issues

Selected Contents: Mapping the Universe of Green Products. The Need for Sustainable Energy Systems. The Transition from Oil Dependency to Sustainability in Denmark. The Revival of Battery-Powered Electric Vehicles in Japan.

Sustainable Urban Mass Transport. The Promise of Sugarcane Ethanol as a Cleaner Combustion Engine Fuel. The Challenge of Sustainable Tourism.

Conclusion: Green Product Innovation and Adoption. ...

Although there are many books on Lean, sustainability, and SHE, few explain how to integrate these dynamic tools. Walking you through this process, this book supplies the tools to create a synergy that will boost efficiencies across all segments of your business.

Follow its advice and you’ll be on your way to making your organization and employees Lean, green, and serene.

Catalog no. K12680, June 2011, 222 pp., Soft Cover ISBN: 978-1-4398-5716-8, $43.95 / £28.99

Catalog no. K12538, July 2011, 226 pp.

ISBN: 978-1-4398-5465-5, $55.95 / £35.99

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19

Lean Methods & Implementation

Toyota Production System An Integrated Approach to Just-In-Time, Fourth Edition Yasuhiro Monden Mejiro University, Tokyo, Japan

A bestseller for decades, Toyota Production System: An Integrated Approach to Just-In-Time supplies indepth coverage of Toyota's production practices, including theoretical underpinnings and methods for implementation. Exploring the latest developments in the Toyota Production System (TPS) framework at Toyota, this edition updates the classic with new material on e-kanban, mini-profit centers, computer-based information systems, and innovative solutions to common obstacles in TPS implementation. Extending the humanized aspect of production introduced in the third edition, the fourth edition explains how to cultivate the culture and way of thinking needed to establish the TPS holistically across your organization.

Catalog no. K11111, October 2011, 566 pp.

ISBN: 978-1-4398-2097-1, $75.95 / £46.99

The Toyota Kaizen Continuum A Practical Guide to Implementing Lean John Stewart Monomoy Capital Partners, Midway, Kentucky, USA

Written by a recognized leader in the manufacturing industry with decades of experience working for Toyota, this book supplies a firsthand account of the realities behind implementing the Toyota Production System (TPS). It presents authoritative insight on how to use the TPS to drive operational value and improvement across all segments of an organization. Highlighting valuable lessons learned directly from the TPS masters at the Toyota factories in Japan, John Stewart provides a time-tested approach for implementing a process of continuous improvement. He explains how to get the process started, get senior management excited about the possibilities, and details a process for implementing the TPS in your organization.

Catalog no. K12059, August 2011, 218 pp.

Soft Cover ISBN: 978-1-4398-4604-9, $43.95 / £28.99

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Progressive Kaizen The Key to Gaining a Global Competitive Advantage John W. Davis There are four different types of Kaizen, each with its own purpose and results.

Companies that understand these differences harness Kaizen’s ultimate power and achieve amazing success in a global manufacturing environment. Written by recognized Lean manufacturing professional John Davis, Progressive Kaizen explains the four distinct types of Kaizen and the particular purpose of each.

Davis clearly elucidates how to exploit Kaizen events and points out why and how Kaizen should be used as a prominent strategy in implementing Lean. This book spells out how to get the utmost from the process of Kaizen and make it a formidable competitive weapon.

Catalog no. K12062, January 2011, 219 pp.

Soft Cover ISBN: 978-1-4398-4608-7, $43.95 / £28.99

Thin Air How Wireless Technology Supports Lean Initiatives Dann Anthony Maurno Salem, Massachusetts, USA

Louis Sirico San Jose, California, USA

This volume proposes practices and paradigms to help readers integrate Lean’s culture of continuous process improvement with wireless technology. It discusses the application of a wide range of wireless technologies, including Wi-Fi, RFID, wireless sensor networks, real-time location systems, and global positioning systems. It addresses the modernization of infrastructure, the elimination of costly hardware and redundant equipment, the facilitation of e-Kanban, and the provision of real-time visibility. The text also includes access to a Lean Wireless ROI Calculator that readers can use to calculate estimated savings in labor and excess capacity.

Catalog no. K10242, April 2010, 251 pp.

ISBN: 978-1-4398-0439-1, $68.95 / £43.99 Also available as an eBook

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Lean Methods & Implementation

Lean Production for Competitive Advantage

Andy & Me Second Edition Crisis & Transformation on the Lean Journey

A Comprehensive Guide to Lean Methodologies and Management Practices

Pascal Dennis Lean Productivity Network

John Nicholas Loyola University, USA

The Lean concepts and principles described in this book have revolutionized manufacturing practice and business conduct in a manner similar to what Henry Ford’s system did for mass manufacturing. Based on three decades of teaching experience, Lean Production for a Competitive Advantage introduces the Lean philosophy and illustrates the effective application of Lean tools with real-world case studies. From fundamental concepts to integrated planning and control in pull production and the supply chain, the text provides a complete introduction to Lean production. Coverage includes small batch production, setup reduction, pull production, preventive maintenance, standard operations, as well as synchronizing and scheduling Lean operations.

Catalog no. K11112, July 2010, 527 pp.

ISBN: 978-1-4398-2096-4, $91.95 / £58.99 Also available as an eBook

Developing Lean Culture in the Process Industries

Joseph Niederstadt Gates Corporation, Suzhou, China

Raymond C. Floyd Suncor, Calgary, Alberta, Canada

Liquid industries, including reactive chemical manufacturing, petroleum and metal refining, and food and bio-pharma production, can make great use of the concepts of Lean. However, largely because they are naturally conservative and more financially stable than most, these industries do not generally make use of Lean manufacturing, and great case stories of successful Lean implementation are rare. This book is the first to offer details and examples of adapting Lean manufacturing to liquid industries. It is based on more than 20 years of industry experience from the legendary Raymond Floyd, one of the first to successfully practice Lean in the chemical industry.

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Catalog no. K11209, December 2010, 192 pp.

Soft Cover ISBN: 978-1-4398-2538-9, $35.95 / £17.99 Also available as an eBook

Standardized Work for Noncyclical Processes

Liquid Lean

Catalog no. PP8629, February 2010, 346 pp.

ISBN: 978-1-4200-8862-5, $57.95 / £36.99 Also available as an eBook

Based on the author's personal experience with Toyota’s master teachers and with companies in the midst of great change, Andy & Me is a business novel set in a failing New Jersey auto plant focusing on the tribulations of Tom Pappas, the plant manager. In a cool, readable style, Andy & Me follows Tom's relationship with Andy Saito, a reclusive Toyota guru whom Tom persuades to help save his plant through the teaching of the legendary Toyota Production System (TPS). On this journey, the reader learns that TPS is more than just a collection of tools; it entails a new way of thinking and behaving.

While most Lean companies adopt methods to standardize cyclical activities, they often fail to apply the same rigor to noncyclical work. This book shows you how to measure non-repeating job processes and eliminate waste associated with noncyclical activities. Laying out the proven methods he has instituted in more than 30 factories around the world, the author details a process for building consistent quality products at reduced costs. Covering activities involving multiple machine job setters, maintenance, stockers, and quality auditors, the text includes a CD with the forms discussed and color versions of the images and charts included in the text.

Catalog no. K11219, August 2010, 120 pp.

Soft Cover ISBN: 978-1-4398-2550-1, $45.95 / £29.99 Also available as an eBook

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Productivity Improvement

Getting Unstuck

Kamishibai Boards

Using Leadership Paradox to Execute with Confidence

A Lean Visual Management System That Supports Layered Audits

Ralph Jacobson Principal - The Leader's Toolbox, Inc.

“I wish I had read this book 20 years ago and avoided wasting my time trying to solve problems when the challenge was a paradox. This is the only book that gets to the heart of insolvable problems and provides a path for resolution.”

—Don Ledbetter, Corporate Director of Management and Organizational Effectiveness, L-3 Communications

“Ralph Jacobson explains that your toughest problem might not be a problem at all, but rather it’s a paradox. ... Jacobson’s breakthrough book gives us tools to achieve higher levels of success, both professionally and personally as we find ways to balance the competing sides of our toughest issues.”

— Kevin Kruse, writing on Forbes.com

This book demonstrates how organization leaders who balance several key paradoxes achieve greater growth and sustainability in the long term than those who use financial data alone. It addresses the issues that are the most troublesome to people and the organizations they work for. The author provides deep insight into the root causes of workplace issues and provides practical language and tools to address the paradoxes that seem to block the achievement of success and life satisfactions.

Joseph Niederstadt Gates Corporation, Suzhou, China

“The Kamishibai process is one of the simplest, but most effective, methods of visual management a company can put into place. ... Joe Niederstadt does a great job of explaining how to use this tool. More importantly, he explains how to take this tool off the production floor and apply it in transactional processes in your back office or support functions.

Follow this blueprint and you can create sustainable Lean processes in your organization.”

—Tim Conrad, Director, Operational Excellence, Gates Corporation

Part of the Toyota Production System, Kamishibai boards are simple and flexible visual controls for performing audits within a manufacturing process. When used properly, they are powerful tools for performing, managing, and auditing tasks of specific duties. This book explains how to use this visual management system to identify normal conditions versus abnormal conditions in your organization. The book includes a CD with master forms you can use to create your own daily, weekly, or monthly Kamishibai cards as well as electronic copies of all examples in the book.

Features:

• Explains the Kamishibai system and its benefits in identifying errors and abnormalities in any manufacturing process

• Lists the types of paradoxes: organization, leader, role, personal, and global

• Provides simple instructions that require minimal training

• Includes easy-to-use tools to appropriately address the specific type of paradox

• Outlines a layered audit system to sustain continuous improvement

• Contains examples where people have actually used the methodologies

Selected Contents:

Catalog no. K20776, September 2013, 169 pp.

ISBN: 978-1-4665-9643-6, $39.95 / £25.99

Introduction to Kamishibai. Formatting the Kamishibai Card. Who Should Use the Kamishibai System. Examples for Who Should Use the Kamishibai System. How the Kamishibai System Works. Kamishibai for TPM. Trifolds. Other Business Applications.

Catalog no. K21443, September 2013, 120 pp.

Soft Cover ISBN: 978-1-4822-0529-9, $49.95 / £31.99

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Productivity Improvement

Quick Changeover Concepts Applied

Achieving Lean Changeover Putting SMED to Work John R. Henry

Dramatically Reduce Set-Up Time and Increase Production Flexibility with SMED

Changeover.com, Fajardo, Puerto Rico, USA

Karsten Herr Shifting from external to internal set-up steps and optimizing your set-up procedure is only the first step in achieving world-class performance. What’s most important is what comes next, cutting down internal set-up times and achieving changeovers that last only a few minutes.

This book provides a comprehensive overview of changeovers from a strategic, tactical, and operational perspective. It outlines specific strategies that can help readers shorten internal set-up steps through the physical analysis of machine elements. The method presented is the result of a synthesis of Shigeo Shingo’s classic single-minute exchange of die (SMED) methodology with modern engineering techniques.

Providing readers with the understanding required to significantly reduce internal set-up times, the book explains why efficient changeovers are critical to production scheduling. It redefines set-up and set-up time and details a step-by-step method for developing quick changeover methods in a manner where changes can be realized with minimal spending.

Properly implemented, the quick changeover concepts presented, can help you reduce set-up times by up to 95 percent.

The book uses language that is easy to understand to make it accessible to all functions along the value stream. It introduces the concept of systems engineering, explains the set-up process and its various elements, and addresses the financial aspects of setup. Maintaining an analytical focus, the text describes the theoretical details and includes numerous application examples for every step.

Catalog no. K20770, December 2013, 168 pp.

ISBN: 978-1-4665-9631-3, $49.95 / £31.99

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Defined as the total process of converting a line or process from one product to another, changeover will not only help your organization improve quality and flexibility, but it will save thousands and sometimes even tens of thousands of dollars per hour.

Achieving Lean Changeover: Putting SMED to Work is about the practical implementation of the single minute exchange of die (SMED) philosophy developed by Shigeo Shingo at Toyota. Although the book is principally about changeover of manufacturing, packaging, and assembly processes, the general concepts and examples are also applicable in lighter industries that require turnover of processes—including airlines, hospitals, operating rooms, and food service.

Filled with practical examples, the book shares proven methods that can help you convert changeover downtime to productive uptime. It explains why reducing changeover time is important financially and provides a structured methodology to help you identify and implement improvement opportunities.

The author addresses both the machinery issues with changeover/ SMED and the associated operational issues such as costs, waiting times, material movement, documentation, and product/component design. He also devotes a chapter to discussing, in detail, how to calculate the cost of changeover downtime, an area that remains a mystery to many.

Presenting time-tested methods and practical examples from a variety of industries, this book offers you the opportunity to reduce changeover time and cost and provide your organization with the flexibility needed to better satisfy its customers.

Catalog no. K14403, December 2012, 205 pp.

Soft Cover ISBN: 978-1-4665-0174-4, $41.95 / £26.99 Also available as an eBook

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23

Productivity Improvement

CrossFunctional Productivity Improvement Ronald Blank Senior Quality Engineer and Productivity Consultant

Using language that is easy to understand, CrossFunctional Productivity Improvement describes how improvement efforts can be undermined by errors and incompleteness. It illustrates the various types of errors that can hurt productivity and outlines proven solutions to prevent or correct them. Explaining how departments not directly related to manufacturing can hinder productivity, it provides time-tested advice on how to reduce waste and enhance efficiency.

The book starts with an overview of traditional productivity improvement methods. Subsequent chapters explain how different departments can affect productivity and describe what must be done to improve productivity. Supplying time-tested procedures for implementing cross-functional productivity actions that are applicable across a wide range of industries, the text describes the problems caused by incorrect Lean manufacturing, material flow, efficiency, ergonomics, quality policies, issues of malpractice, and counterproductive procedures.

• Provides the technical information needed to implement sustainable productivity improvements • Addresses the problems often caused by incorrect Lean manufacturing and issues of malpractice • Includes an extensive glossary and a list of suggested readings to help readers further explore productivity improvement Readers will gain a clear understanding of exactly what to do and what not to do in all aspects of company operations to maximize productivity through a cross-functional approach. Furthermore, the book will enable companies to take better advantage of all that the ISO 9001 and similar systems have to offer by making best use of the interactions between the various elements of company operations.

Catalog no. K14795, September 2012, 174 pp.

ISBN: 978-1-4665-1073-9, $52.95 / £33.99 Also available as an eBook

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The Basics of Self-Balancing Processes True Lean Continuous Flow Gordon Ghirann “Instead of explaining merely the typical approach that seeks to balance the work and operates strictly according to takt time, Gordon’s method takes advantage of the ‘human element’ and releases the full potential of the employees. … …Until now, there was no source for this powerful concept outside of some limited research on the web.

Gordon, however, has probably experimented more with Self-Balancing than anyone else, so I’m very excited that he has finally brought this powerful concept to you.”

—Kirk Paluska, Lean Transformations Group

Using a well-tested method for successful improvements initiated by the author, this is the first book to explain how to achieve continuous flow in both simple and complex manufacturing environments. It describes how to recognize and resolve weak links to ensure continuous flow in your manufacturing operations. The book offers rules, tools, and guidelines to help you not only solve problems at the root, but even eliminate them before they start. It reviews the shortcomings of traditional assembly line balancing and walks readers through the new paradigm of SelfBalancing.

• Demonstrates the real power, flexibility, and breakthroughs that this method can have on manufacturing • Provides a shortcut to achieving true continuous flow in your operations • Offers many solutions to the problems and shortcomings associated with standard line balancing, such as inventory buffers, variation, operator pace

Selected Contents: Conventional Continuous Flow. Shortcomings. SelfBalancing. Back-Bench Operations. Debugging. Parts and Tool Presentation. Software.

Catalog no. K11034, February 2012, 108 pp.

Soft Cover ISBN: 978-1-4398-1965-4, $20.95 / £13.99

Phone 1.888.319.5852 Fax 1.800.394.6286 Online ProductivityPress.com

Productivity Improvement

The Basics of Line Balancing and JIT Kitting Beverly Townsend Accessible to the Lean novice and shop floor employee, The Basics of Line Balancing and JIT Kitting explores line balancing and the pre-assembly of components into a finished product in a just-in-time fashion (JIT Kitting).

It explains how to use time studies, develop yamazumi charts, discover and eliminate waste, balance your line, and create new standard work content for the shop floor.

The book facilitates a clear understanding of the seven deadly wastes (muda) as well as what you can do to eliminate them from your facility. Describing the purpose and use of standard work, it explains how to properly staff work cells and how to develop flex plans for fluctuations in demand using this data. The first few chapters explain how to determine takt time and how to use that information along with time studies to identify when you are not meeting customer demand.

• Written by a former Toyota employee with years of experience • Illustrates culture change and self-driven improvement from the shop floor • Offers solutions to the problems and shortcomings associated with standard line balancing The chapters on JIT Kitting explain how there are other advantages to kitting besides eliminating waste and increasing productivity. The book explains how you can use JIT Kitting to improve quality by having the parts available and limiting the options of numerous parts to the operator. It also provides the understanding needed to ensure the right parts are installed.

Catalog no. K13891, April 2012, 85 pp., Soft Cover ISBN: 978-1-4398-8237-5, $20.95 / £14.99 Also available as an eBook

Equipment Management in the PostMaintenance Era A New Alternative to Total Productive Maintenance (TPM) Kern Peng Santa Clara University, California, USA

“If you are at all responsible for equipment management, especially in high tech, you need to read this book. And give it to your boss. Dr. Peng has illustrated in great detail why equipment maintenance should no longer be considered a standalone function but rather a strategic competitive opportunity that impacts all facets of the organization.”

—Kurt A. Beiter, PhD., Dept. of Mechanical Engineering, Stanford University

Providing a fundamental understanding of equipment management, this book presents novel alternatives in equipment management beyond the mainstream principles of maintenance management. These new alternatives are pioneered by high-tech industries and are driven by the fast-changing environment. The text aims to initiate new thinking and approaches that will help organizations in high-tech industries manage their expansive equipment as well as prepare companies in traditional industries for the spreading of the microchip era in their equipment base.

• Covers maintenance logistics such as planning for headcount, budget, and inventory management • Highlights the fundamental internal flaw in maintenance organizational setup • Provides a systems model for analyzing equipment management • Proposes new approaches to replace maintenance functional setup • Outlines a transformation and implementation process

Selected Contents: Introduction to Equipment Management. History of Equipment Management. Introduction to the PostMaintenance Era. General Maintenance Concepts and Practices. Maintenance Management Logistics.

Maintenance Performance Indicators. Computerized Maintenance Management Systems. The Systems View of Equipment Management Process. New Changes in the Post-Maintenance Era. Transformation and Implementation.

Catalog no. K14409, April 2012, 255 pp.

ISBN: 978-1-4665-0194-2, $52.95 / £33.99 Also available as an eBook

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25

Productivity Improvement

Lean Production for the Small Company Mike Elbert Elbert Lean Business Systems

This hands-on guide to adapting Lean principles and the Toyota Production System to high-mix/lowvolume environments uses charts, pictures, and easyto-understand language to describe the methods needed to improve processes and eliminate waste. It walks readers through the correct order of implementation and describes problems and pitfalls along with time-tested solutions. Explaining how to incorporate existing systems into a Lean strategy, the book starts with the fundamentals and builds on them to describe the full range of tools and processes needed to implement Lean.

Catalog no. K13607, August 2012, 295 pp.

Soft Cover ISBN: 978-1-4398-7779-1, $52.95 / £33.99 Also available as an eBook

The 12 Pillars of Project Excellence A Lean Approach to Improving Project Results Adil F. Dalal CEO, Pinnacle Process Solutions Intl., Cedar Park, Texas, USA

Winner of a 2013 Axiom Business Book Award The 12 Pillars of Project Excellence will help readers transform the theory of project management from the age of command, control, and chaos to a solid practice of project leadership that engages, empowers, and enlightens. Asking tough questions about the current state of project management, it provides powerful tools for organizational and self assessment on the accompanying CD. The author unveils novel solutions and breakthrough concepts based on the lessons learned from leading over 300 successful projects to help you chart the most efficient path to the pinnacle of project leadership.

A Factory of One Applying Lean Principles to Banish Waste and Improve Your Personal Performance Daniel Markovitz President, TimeBack Management

This book describes how to improve your performance by applying Lean methods to your work. It translates powerful Lean tools such as visual management, flow, pull, 5S, and kaizen to your daily work, revealing how they can help to improve efficiency, reduce waste, and link you ever more closely to customer value. Helping you develop better self-awareness, more disciplined problem-solving skills, and the ability to self-correct errors, the book teaches you how to find the root causes underlying your inefficiencies so you can eliminate them permanently.

Catalog no. K12737, December 2011, 177 pp.

Soft Cover ISBN: 978-1-4398-5993-3, $27.95 / £17.99

Toyota Kaizen Methods Six Steps to Improvement Isao Kato TMI, Aichi, Japan

Art Smalley Art of Lean, Huntington Beach, California, USA

This workbook is the first of its kind to document and outline the actual kaizen practices taught within the Toyota Motor Corporation to develop leadership skills and personal responsibility close to the manufacturing floor. By explaining in full context the six basic kaizen principles that govern Toyota, the authors enable readers to improve their own skills and those of their employees making full use of the kaizen approach. The text examines simple analytic methods for work elements, time, motion, production lead-time, machine losses, and standardized work.

Catalog no. K11748, October 2010, 156 pp.

Soft Cover ISBN: 978-1-4398-3853-2, $57.95 / £36.99

Catalog no. K12221, October 2011, 691 pp.

Soft Cover ISBN: 978-1-4398-4912-5, $71.95 / £44.99

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Productivity Improvement

Visual Controls

Quality Management

Applying Visual Management to the Factory

Theory and Application

Chris A. Ortiz and Murry Park

Peter D. Mauch

Leaving little to chance, this book provides a detailed explanation of how to apply the Lean principles of 5S to convert a factory to a fully functioning Visual Workplace. It covers the range of methods that compose an effective visual management system and explains management's role in creating a Lean strategy to accomplish the transformation. The text covers visual Kanban, material replenishment, and the implementation of a visual maintenance department. Describing how to hasten the required cultural changes, it also includes step-bystep instructions for creating visual shadow boards.

Quality is not an engineering discipline, but a business practice. Dr. Peter D. Mauch offers his expertise in this groundbreaking book, demonstrating the necessity of quality as a sustained management activity. Divided into five sections, the book covers staffing, motivation, control, planning, and organization. It offers quality management practices and discusses the impact of managing for quality throughout an organization. The book addresses the alignment of individual departments to maximize quality, business planning and success metrics, record keeping, and department level quality control implementation and deviations.

Catalog no. K11109, December 2010, 180 pp.

Soft Cover ISBN: 978-1-4398-2090-2, $45.95 / £29.99

Catalog no. K10712, December 2009, 171 pp.

ISBN: 978-1-4398-1380-5, $59.95 / £31.99 Also available as an eBook

The OEE Primer

Listening to the Voice of the Market

Kaizen Assembly, Inc., Bellingham, Washington, USA

Understanding Overall Equipment Effectiveness, Reliability, and Maintainability

How to Increase Market Share and Satisfy Current Customers

D.H. Stamatis

R. Eric Reidenbach

President, Contemporary Consultants Co., Southgate, Michigan, USA

Market Value Solutions, Hattiesburg, Mississippi, USA

Breaking down the OEE methodology from a historical perspective, this book explores the overall effectiveness of machines and unveils novel design improvement methods, including hazard analysis, rate of change of failure analysis, failure rate finite element analysis, and theory of inventive problem solving. It covers loss of effectiveness, new machinery, electrical maintenance issues, Weibull distribution, measurement techniques, and mechanical and electrical reliability. Highlighting mechanical and electrical opportunities throughout, the text includes a CD with more than 100 pages of appendices and additional resources.

In this book, Dr. Reidenbach teaches you how to identify and capture the voice of the market and then use that data to make your organization market focused.

With this book as your guide, you will learn how to develop surveys that are more than skin deep, deliver them to the right people, collect information that is useful, and then turn that information into action steps that will help you cultivate customers who feel listened to, which is the first step in building loyal relationships.

Catalog no. PP9330, December 2009, 205 pp.

ISBN: 978-1-4200-9330-8, $65.95 / £42.99 Also available as an eBook

Catalog no. K10723, June 2010, 502 pp., Soft Cover ISBN: 978-1-4398-1406-2, $62.95 / £40.99 Also available as an eBook

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27

Organizational Culture

Creating a Lean Culture Tools to Sustain Lean Conversions, Second Edition David Mann Principal, David Mann Lean Consulting, Michigan, USA

"The new insights included in this second edition of Creating a Lean Culture, affirm our examiners recommendations in 2006 to recognize this original work with the Research and Professional Publication Award."

—Robert D. Miller, Executive Director, The Shingo Prize for Operational Excellence

The new edition of this Shingo Prize-winning international bestseller shows you how to implement a Lean transformation that really works by developing a culture that builds success from the top down and the bottom up at the same time. If you are a leader at any level in an organization undergoing or considering a Lean transformation, this is the book you must read.

Improved throughout, this edition offers new guidance on Lean management in discrete manufacturing, office, and process manufacturing environments, provides specifics on engaging executives through Gemba walks and offers several new case studies as well as invaluable lessons that David Mann has learned since the first edition went to print.

Empowered with five more years of accumulated knowledge and experience, David Mann’s Shingo Prize-winning book: • Offers new guidance on how to begin implementing Lean management in discrete manufacturing, office, healthcare, and process manufacturing environments • Explains how to engage executives through gemba walks • Expands the Lean management assessment based on actual use, and now offers two versions (both available online) one for manufacturing and one for administrative, technical, and professional settings Catalog no. K10570, March 2010, 316 pp.

Soft Cover ISBN: 978-1-4398-1141-2, $45.95 / £29.99 Also available as an eBook

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The Lean Practitioner's Field Book Proven, Practical, Profitable and Powerful Technigues for Making Lean Really Work Charles Protzman, Fred Whiton, Joyce Kerpchar, Christopher Lewandowski, Steve Stenberg, and Patrick Grounds “There are miles between understanding Lean and being a Lean Practitioner. The Lean Practitioner’s Field Book is a must-read for those who want to close the gap.”

—Rob Mionis, Operating Partner, Pamplona Capital Management, Former President and CEO, StandardAero

Outlining a true learning path for anyone seeking to understand essential Lean principles, this book provides a plethora of examples drawn from the personal experiences of its many well-respected and awardwinning contributors. These experts break down Lean concepts to their simplest terms to make everything as clear as possible for Lean practitioners. A refresher for some at times, the text provides thought-provoking questions with examples that will stimulate learning opportunities.

Introducing the Lean Practitioner concept, the book details the five distinct Lean Practitioner levels and includes quizzes and criteria for each level. It highlights the differences between the kaizen event approach and the Lean system level approach as well as the difference between station balancing and baton zone.

This book takes readers on a journey that begins with an overview of Lean principles and culminates with readers developing professionally through the practice of self-reliance. Providing you with the tools to implement Lean tools in your organization the book includes discussions and examples that demonstrate how to transition from traditional accounting methods to a Lean accounting system.

Catalog no. K13402, August 2014, 1584 pp.

ISBN: 978-1-4398-7336-6, $99.95 / £63.99

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Organizational Culture

Learning with Lean

Manufacturing Technology Transfer

Unleashing the Potential for Sustainable Competitive Advantage

A Japanese Monozukuri View of Needs and Strategies

James Zurn and Perry Mulligan

Yasuo Yamane Hiroshima University, Japan

QLogic Corporation, Aliso Viejo, California, USA

Tom Childs

Examining the performance gap between good organizations and great ones, Learning with Lean: Unleashing the Potential for Sustainable Competitive Advantage explains how to use Lean as a learning vehicle for achieving and sustaining a competitive advantage.

Helping you better understand the current state of your organization, the book outlines a series of five simple phases for developing an architecture and implementation plan to transform your organization’s performance. These five phases fit neatly into a closed-system model that has similarities to the PlanDo-Check-Act quality model. The model is simple, easy to communicate, and easy to implement— Assess, Plan, Prepare, Do, and Learn.

• Supplies a brief overview of Lean tools • Provides an understanding of the Voice of the Customer as a focusing engine • Covers measurement and goal setting • Illustrates the dynamics of organizational change • Explains how to boost learning through Lean The authors guide you through the deployment of training and the implementation of new knowledge and skills around Lean. In addition, they also explain how to find and improve on the areas where waste exists so your organization can reinvent the way it learns.

Effective management techniques recognize the need for balance, and this book is no different. Helping you pinpoint where those balances and dichotomies exist, it arms you with powerful techniques to manage these challenges and to transform your organization into a change-hungry Lean learning organization with a sustainable competitive advantage.

Catalog no. K16629, August 2013, 294 pp.

Soft Cover ISBN: 978-1-4665-7294-2, $49.95 / £31.99

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University of Leeds, West Yorkshire, UK

Based on a bestselling book originally published in Japanese, Manufacturing Technology Transfer: A Japanese Monozukuri View of Needs and Strategies offers time-tested methods and littleknown tips for achieving successful transfer of technology along with the skills required to operate that technology. Designed to support a series of lectures on technology transfer within a master’s course on the management of technology, it presents the results of years of research carried out at Hiroshima University.

The book delves into the authors’ decades of experience transferring technology between Japan and the rest of the world. It presents case studies of successful technology transfers from both the ship building and food equipment industries. Its wide-reaching coverage examines methods of skill transfer, production management, and manufacturing company classification.

Introducing readers to the engineering activities that occur within the manufacturing industry, the book illustrates the engineering technology activities involved in manufacturing, along with the production management activities required to support them. It also explains how job simulators can help shorten learning times in the manufacturing industry in the same way that flight simulators are used to teach flying skills to pilots.

The book outlines a framework for teaching and learning processes that can be visualized in terms of an Sshaped learning curve. It explains how technology transfer overseas should be supported by contractual agreements between the parties concerned. Detailing the legal/contractual responsibilities for all parties involved, it also describes what you should do if problems arise during the transfer.

Catalog no. K16350, March 2013, c. 236 pp.

ISBN: 978-1-4665-6763-4, $59.95 / £38.99

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29

Organizational Culture

Green Power Perspectives on Sustainable Electricity Generation Edited by

Joao Neiva de Figueiredo Saint Joseph’s University, Philadelphia, Pennsylvania, USA

Mauro F. Guillén The Wharton School, University of Pennsylvania, USA

Green Power: Perspectives on Sustainable Electricity Generation provides a systematic overview of the current state of green power and renewable electrical energy production in the world.

Presenting eight in-depth case studies of green power production and dissemination, it illustrates the experiences and best practices of various countries on this topic of critical importance.

The book’s case studies provide readers with policy, business, and societal perspectives. They examine the differences in each country’s natural endowments, cultural make-up, technological development, publicpolicy concerns, and institutional incentive structures relative to the advancement of green and sustainable energy.

• Considers China’s energy profile and what is being done to reduce its reliance on coal • Describes the cultural foundations and institutional environment that gave birth to Germany’s energy revolution • Reports on French Polynesia’s progress in its quest to generate half of its electricity from renewable sources • Investigates the feasibility of biomass as a largescale electricity generation option • Explores the vision of power generation in space By illustrating the experiences of other nations, the book outlines valuable lessons learned and best practices that can be extremely helpful to other countries as they seek a greener energy profile. Supplying a timely overview of renewable and non-renewable electric power sources, it provides in-depth analysis of the key factors that affect success. It also identifies practices that have been precursors to failure so you can avoid making the same mistakes in your quest to contribute to the long-overdue advancement of green energy.

Catalog no. K20467, February 2014, 603 pp.

ISBN: 978-1-4665-9048-9, $69.95 / £44.99

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Building a Global Learning Organization Using TWI to Succeed with Strategic Workforce Expansion in the LEGO Group Patrick Graupp, Gitte Jakobsen, and John Vellema “This book, written with LEGO insiders, is a stunning example of the discipline and commitment needed to develop people as masters of their crafts through the only way people learn—repetitive, deliberate practice.”

—Jeffrey K. Liker, Professor, University of Michigan; and Shingo Prize-winning author of The Toyota Way

Building a Global Learning Organization: Using TWI to Succeed with Strategic Workforce Expansion in the LEGO® Group describes how a multinational company developed a global structure for learning based on the TWI (Training Within Industry) program to create and sustain standardized work across multiple language and cultural platforms.

In this book, Shingo Prize-winning author Patrick Graupp collaborates with two practitioners who performed the planning and implementation of the LEGO Group’s worldwide Learning Organization.

The book outlines the organizational and planning models used by the LEGO Group to create the internal ability to give and receive tacit skills and knowledge. Describing how and why TWI is used as the foundation for success in knowledge transfer across diverse languages and cultures, it provides step-bystep guidance on how to establish a solid organizational foundation for your own Learning Organization..

Selected Contents: Laying the Groundwork. Setting the Course.

Preparing for the Global Pilot Project. Setting the Foundations for Moving Forward. The Global Pilot Project. Testing the Global LEGO Training Organization and TWI JI. The Workshops. Creating the Global Lego Training Organization. Building the Organization. Learning Tools and Methodologies.

Rollout. Sustaining the Effort and Growing the Future. Case Studies from the Implementation.

Catalog no. K21725, June 2014, 237 pp., Soft Cover ISBN: 978-1-4822-1363-8, $49.95 / £31.99 Also available as an eBook

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Organizational Culture

People, Process, and Culture

Sustainable Lean The Story of a Cultural Transformation

Lean Manufacturing in the Real World

Robert B. Camp

Jeffrey P. Wincel and Thomas J. Kull, PhD

Burlington Medical Supplies Inc., Newport News, Virginia, USA

“... rather than learn the hard way, this book can serve as a trainer-coach, helping you and your organization make the Lean transformation by exposing where your values, or thinking, may also have some gaps. ... It will help Lean champions pinpoint where specifically their team, their leadership, and their organizations may struggle with the Lean mindset.”

If you’ve employed consultants and embarked on a Lean transformation only to find your efforts stall after the consultants leave, this book will teach you what you must do to stay the course over the long term. Using a compelling novel format, Sustainable Lean: The Story of a Cultural Transformation illustrates the process of implementing a sustainable Lean transformation.

—Michael Hoseus, Co-Author of Toyota Culture: The Heart and Soul of the Toyota Way

Examining Lean processes in the context of the authors’ academic research in-progress, People, Process, & Culture: Lean Manufacturing in the Real World illustrates the impact of culture on the implementation of Lean Manufacturing (LM) across various geographic and cultural areas. It identifies cultural values, as examined against Lean Manufacturing disciplines, and derives culturally based Lean Manufacturing (LM) values. It then assesses these cultural values in light of specific LM components, such as PULL systems and TPM, to demonstrate varying perspectives and applications.

The book supplies time-tested advice to help you sort through the flood of information on Lean techniques and culture. It examines the numerous Lean components currently being deployed successfully around the world and identifies the limitations that can result from the varying interpretations and applications of Lean systems.

Lean culture is all about Lean vision, mission, and values. This book not only identifies the Lean values required, but also supplies the understanding to integrate these values across all levels of your organization.

The book follows Jim, the plant manager of an electronics firm that has already seen its first Lean initiative fail. Jim realizes that if he doesn’t act quickly, his job and the jobs of everyone in the factory might be in jeopardy. Jim meets a Lean consultant who agrees to help him implement and sustain a new transformation. Readers follow along as Jim learns invaluable lessons that help him and his plant see costs plummet, on-time delivery reach nearly 100 percent, and defects drop by close to 80 percent.

Using simple terms and an ongoing example, the book demonstrates how to use top-down metrics to identify strategic and tactical opportunities for improvement. It describes how to conduct Hoshin Kanri (strategic policy deployment). It also describes the relationship between top-down metrics, organizational accountability, the breaking down of "stovepipes," and the concept of "alignment" that comes about as the result of Hoshin Kanri.

Detailing a data-driven methodology to help you set boundaries for effective decision making, this book will inspire manufacturers to achieve world-class production and efficiency standards—one factory, one business at a time.

Catalog no. K16554, March 2013, 183 pp.

Soft Cover ISBN: 978-1-4665-7168-6, $29.95 / £18.99

Catalog no. K15494, April 2013, 153 pp.

ISBN: 978-1-4665-5789-5, $49.95 / £31.99

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31

Organizational Culture

Achieving HR Excellence through Six Sigma Daniel Bloom

Relentless Improvement True Stories of Lean Transformations Bill Trudell

Daniel Bloom & Associates, Inc., Largo, Florida, USA

Relentlessexcellence.com, Bradenton, Florida, USA

“This book offers an excellent review of Six Sigma principles and a wonderful application of those principles to streamline and improve HR practices. Application of these ideas will mitigate the risks of HR by reducing variance and increasing certainty of HR work. These are the foundation principles which ensure that HR will deliver sustainable value.”

Tracing the author’s decades-long continuous improvement journey, Relentless Improvement: True Stories of Lean Transformations walks readers through vivid shop floor experiences to convey a genuine feel for the environments in which Lean Six Sigma transformations occur. Recounting numerous Lean Six Sigma transformations, it illustrates the spectrum of successful operational tactics.

—Dave Ulrich, Professor, Ross School of Business, University of Michigan

The story starts just outside Detroit, Michigan in the 1970s when the auto industry was booming, and most people in the area worked in the car factories, or in one of the component factories that supplied the Big Three. The complexity and detail of the projects grow chapter by chapter. The book begins by explaining how to manage Lean basics such as applying 5S, shortening product cycle times, and creating standard work. It then progresses to factory Lean Six Sigma transformations. Providing implementation guidance geared to functions on the operational level, the book:

From the history and evolution of the Total Quality movement to initiatives for introducing a Six Sigma continuous process improvement strategy in your HR department, this book introduces a new way to envision your role within the organization. It explains how this powerful methodology works and supplies a roadmap to help you find and eliminate waste in your HR processes. The book outlines dozens of proven approaches as well as a hierarchy of the exact steps required to achieve it.

• Introduces a new way for HR to envision their role within the organization • Provides a roadmap to help readers find hidden wastes in their HR processes • Explains how to implement Six Sigma into the transformational side of the organization • Describes how to build a new business model for HR in your organization

Selected Contents: What Do We Mean by HR Excellence? Where Did Six Sigma Come From? What Is Six Sigma? Six Sigma Tool Box. In Plain Sight: Sources of Wastes. Applied Six Sigma and Human Capital Management.

Business Model Canvas and HR Management.

Bringing It All Together. Achieving HR Excellence through Six Sigma.

Catalog no. K20294, August 2013, 215 pp.

Soft Cover ISBN: 978-1-4665-8646-8, $39.95 / £25.99

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• Presents stories based on the author’s interactions with company leaders and shop-floor employees in the midst of great change • Illustrates real-world plant politics and manufacturing situations using compelling stories • Highlights valuable lessons learned at the end of each chapter The book recounts the author’s career experiences to provide you with a real-world understanding of how to use Lean tools. The stories in the book illustrate everything from standard work and takt time to kaizen events and Total Productive Maintenance. The text also includes accounts of "front end" or administrative processes such as product development and materials handling.

Catalog no. K15311, November 2012, 237 pp.

ISBN: 978-1-4665-5430-6, $41.95 / £26.99 Also available as an eBook

Phone 1.888.319.5852 Fax 1.800.394.6286 Online ProductivityPress.com

Organizational Culture

The Workforce Engagement Equation

The 7 Kata Toyota Kata, TWI, and Lean Training Conrad Soltero & Patrice Boutier

A Practitioner’s Guide to Creating and Sustaining High Performance

TMAC

Winner of a 2013 Shingo Prize for Operational Excellence!

Jamison J. Manion Workforce Engagement Solutions, LLC, USA

The Workforce Engagement Equation is for the hands-on leaders engaged in the frontline of affecting change—those who bear the scars of past failed initiatives yet continue to persevere. Describing the science behind the "Art of Managing" process improvement, it will help you bridge the gap between strategy and tactics and allow you to take concrete action to control ongoing operations sustainably.

This step-by-step guide lays out the principles, tools, and techniques that have proven effective in leading and managing the "people side" of process improvement. The book demystifies the complexity of organizational change with easy-to-understand explanations, intuitive graphics, and real-world examples.

Filled with helpful practical knowledge, such as the Seven Cardinal Sins of Change Leadership, it will help you assess exactly where your organization is along the change continuum and what actions will help propel your organization to higher levels of organizational effectiveness.

• Presents methods that can be applied in any organization and situation • Supplies guidance on how to build systems and implement performance metrics • Offers solutions to real-world problems • Integrates powerful concepts from multiple disciplines This book provides you with the tools to make a difference in the performance of your organization and the engagement of your workforce. To help you construct your own organizational vessel and navigate the murky waters of organizational change, the text includes a CD with each assessment, form, template, and example project plan contained in the book.

Catalog no. K13095, July 2012, 590 pp., Soft Cover ISBN: 978-1-4398-6809-6, $52.95 / £33.99

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Bridging the kata/TWI nexus, this book details a roadmap for Lean success. It presents many of the disjointed Lean practices and explains why the mix of kata and TWI is a successful recipe for continuous improvement. After introducing kata, the authors reveal the many katas inherent in the three major TWI courses and the TWI Job Safety course. The text covers such Lean concepts as gemba walks, PDCA, reflection, proper coaching, grasping the situation, and digging deeply.

• Describes the roles of teaching, coaching, and training for Lean • Contextualizes Lean concepts like gemba walks, genchi gembutsu, and PDCA • Explains the value stream analysis relationship to the kata and the kata's relationship to TWI job instruction • Provides guidelines for coaching the kata and for training job instruction

Selected Contents: Historical Perspective. Eastern Thought and the Kata.

TWI History. Lean & TPS. Summary. Lean Training: What Effective Lean Training Isn't. Why One-On-One OJT is Best. TWI and Task Standardization. Job Instruction - The Improvement Platform. Job Relations - Can't We All Just Get Along? Does Job Methods Really Take Too Long? Muri - Safety is Reasonable. The Other 2 TWI Courses. Summary.

Improvement Kata: Work Hardening Your Brain for Adaptability. Toyota Kata and Improvement Standardization. When Kaikaiku Is Not Possible.

Grasping, PDCA, Reflection. Summary. Application: Lean Tools and Lean Practices. The Job Instruction and Kata Escalator.

Catalog no. K13797, June 2012, 191 pp., Soft Cover ISBN: 978-1-4398-8077-7, $52.95 / £33.99 Also available as an eBook

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33

Organizational Culture

Value Engineering Synergies with Lean Six Sigma

New Horizons in Standardized Work

Combining Methodologies for Enhanced Results

Techniques for Manufacturing and Business Process Improvement

Jay Mandelbaum, Anthony Hermes, Donald Parker, and Heather Williams This book describes how to integrate Lean Six Sigma (LSS), Design for Six Sigma (DFSS), and Value Engineering (VE) to go beyond what is currently possible with the individual approaches. Explaining the VE methodology, it supplies a high-level discussion of LSS and DFSS. Next, it compares VE with LSS and identifies the different opportunities for synergies that can provide your organization with a competitive edge. The ideas and synergies presented in this book can help industry professionals and those in government accelerate the adoption of efficiencies in their operations.

Catalog no. K14412, May 2012, 212 pp., Soft Cover ISBN: 978-1-4665-0201-7, $52.95 / £33.99 Also available as an eBook

Timothy D. Martin and Jeffrey T. Bell This all-inclusive guide facilitates an understanding of standardized work principles and the logic behind their development. In a step-by-step format, it discusses the relationship of the work period and the takt time, as well as the importance of the three main worker interface levels in job design. It includes an array of examples that demonstrate how the concepts discussed can be applied across a wide range of industries—including health care, construction, business processes, and food services.

Catalog no. K11891, January 2011, 179 pp.

Soft Cover ISBN: 978-1-4398-4080-1, $55.95 / £35.99 Also available as an eBook

Feedback Toolkit

TWI Case Studies

16 Tools for Better Communication in the Workplace, Second Edition

Standard Work, Continuous Improvement, and Teamwork

Rick Maurer

Donald A. Dinero

Maurer & Associates, Arlington, Virginia, USA

Round Pond Consulting, Rochester, New York, USA

Written by a noted authority in leadership and change management, the second edition of this popular toolkit provides expert guidance on using feedback as a performance improvement tool. Describing best practices, it supplies the understanding required to effectively give and receive feedback across a wide range of work situations. The book makes the feedback process easy to understand with a detailed six-step framework. It covers specific feedback tools and illustrates approaches for applying them in a variety of management scenarios—including situations where giving feedback feels more like giving an acid bath.

TWI Case Studies provides the insight of leading experts to assist in the execution of Training Within Industry (TWI). Presented as a series of case studies from a range of corporations—including IBM, Ben & Jerry's, and US Synthetic—it illustrates the rebirth of TWI programs in the United States.

Demonstrating how TWI can benefit any and all organizations, the book details the specific activities decision-makers need to accomplish to successfully incorporate TWI into the business culture—including the Ten Points for Implementing and Sustaining the TWI "J" Programs.

Catalog no. K11899, January 2011, 81 pp.

Soft Cover ISBN: 978-1-4398-4093-1, $18.95 / £12.99

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Catalog no. K12063, April 2011, 136 pp., Soft Cover ISBN: 978-1-4398-4610-0, $43.95 / £26.99

Phone 1.888.319.5852 Fax 1.800.394.6286 Online ProductivityPress.com

Organizational Culture

Introduction to Hazard Control Management

Lean Safety Transforming Your Safety Culture with Lean Management Robert B. Hafey

A Vital Organizational Function

RBH Consulting LLC, Homer Glen, Illinois, USA

James T. Tweedy International Board for Certification of Safety Managers, Helena, Alabama, USA

The International Board for the Certification of Safety Managers (IBFCSM) has designated this text as the Primary Study Reference for those preparing to sit for the Certified Hazard Control Manager (CHCM) and the Certified Hazard Control Manager-Security (CHCM-SEC) Examinations. Introduction to Hazard Control Management: A Vital Organizational Function explains how proven management and leadership principles can improve hazard control and safety management effectiveness in organizations of all types and sizes.

The text addresses hazard control and safety management as organizational functions, instead of just programs. It not only supplies a broad overview of essential concepts—including identifying, analyzing, and controlling hazards—but also promotes the importance of safe behaviors.

• Addresses the inter-relationships of various organizational functions that support hazard control, accident prevention, and safety • Includes an overview of emergency management, hazardous materials, and fire safety management • Reviews occupational health, radiation safety, and emerging hazards such as nanotechnology and robotic safety Written by the executive director of IBFCSM, the book covers a broad array of hazards that can exist in most organizations. It focuses on the need to use good leadership, effective communication, and proven management techniques to prevent organizational losses.

“This much-needed book provides real practical examples of how safety and Lean teams working on their own improvement journeys can come together and drive easier, cleaner, and safer work environments and practices for the employees of any business.”

—Dan McDonnell, Lean Initiative Manager, General Electric Transportation

While worker safety is often touted as a company’s first priority, more often than not, safety activity is driven by compliance to legislation rather than any safety improvement initiative. Lean takes a proactive approach—it is not contingent on legislation. A serious Lean effort will tear apart an old inefficient entitlement-riddled culture and build it into something effective.

Lean Safety: Transforming Your Safety Culture with Lean Management takes lessons learned from Lean and applies them to the building of a world-class safety-first organization. Based on 30 years of experience with successful implementation of continuous improvement, Robert Hafey focuses the power of Lean improvement on the universal topic of safety. In doing so, he shows how Lean and safety are linked— that the achievement of one is often dependent upon achievement of the other.

Any lasting improvement must become both institutionalized and perpetually capable of adaptation.

World-class safety is not about writing correct rules, but more about righting the culture responsible for the well-being of its stakeholders.

Catalog no. K10844, December 2009, 186 pp.

Soft Cover ISBN: 978-1-4398-1642-4, $45.95 / £29.99

Emphasizing the importance of effective communication skills in hazard control efforts, this book promotes an understanding of system safety methodologies and organizational culture to help you control hazards, prevent accidents, and reduce other losses in your organization.

Catalog no. K15178, September 2013, 308 pp.

ISBN: 978-1-4665-5158-9, $99.95 / £63.99 Also available as an eBook

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35

Lean Leadership

The Product Wheel Handbook Creating Balanced Flow in High-Mix Process Operations Peter L. King and Jennifer S. King “The authors have a gift for writing well, in a way that will keep the reader connected throughout this excellent work. It flows through the methodology in a well-structured and logical way and could only be written by someone who has lived through product wheel implementation many times ... definitely a must-read for any Lean practitioner.”

—Henrique Fagundes, Senior Project Manager, DuPont

“A clearly written guide to designing and improving product wheels ... . Pete and Jennifer King take you through a logical step-by-step process without ever resorting to simplistic recipes. This book will be valuable to businesses where both pull and push systems apply. Highly recommended!”

—Peter C. Compo, Director of Integrated Business Management, DuPont

The product wheel (PW) design process has practical methods for finding the optimum sequence, therefore minimizing changeover costs and freeing up useful capacity. This book describes this proven technique for dealing with all of the issues related to multiple product situations. It walks the reader through a logical, detailed, step-by-step process for designing and implementing the PW technique. Breaking down a fairly complex design process down into discrete, practical, manageable steps, it includes a case study from actual practice that illustrates the design process and the benefits.

Features: • Describes a practical and proven technique for dealing with the issues related to multiple product situations • Provides a step-by-step process for designing and implementing the techniques • Includes a case study that illustrates the design process

The Expanded and Annotated My Life and Work Henry Ford's Universal Code for World-Class Success William A. Levinson, Henry Ford, and Samuel Crowther “... provides insight into business practices and a deeper understanding of his universal code for world-class success which was very applicable during that period. There are also useful guidelines as to how these principles can be applied to modern-time challenges.”

—Nazanin Mehrooz, in PMI World Journal, Vol. II, Issue XI

Henry Ford's industrial innovations were directly responsible for the transformation of the United States into the most productive, affluent, and powerful nation on Earth. My Life and Work describes exactly how Ford did this in terms of not only manufacturing science, but also economics and organizational behavior. This holistic approach, and its validation by world-class results, make Ford's original work one of the best business leadership book ever written.

The Expanded and Annotated My Life and Work: Henry Ford's Universal Code for World-Class Success updates this original with modern perspectives that explain and organize Ford’s thought process explicitly. This annotated edition introduces Ford’s universal code along with vital economic, behavioral, Lean manufacturing, and customer service principles.

It contains almost all the material of the original, plus more than 30 percent new content that reinforces Ford’s timeless principles.

Readers who understand and internalize Ford’s universal code can easily overcome the self-limiting paradigms that afflict today’s organizations. The book illustrates the basic elements of what is now called the Toyota Production System as well as the organizational and human relations principles needed to gain buyin and engagement from all participants.

Catalog no. K15486, April 2013, 319 pp.

ISBN: 978-1-4665-5771-0, $49.95 / £31.99

Catalog no. K15304, April 2013, 219 pp., Soft Cover ISBN: 978-1-4665-5418-4, $49.95 / £31.99

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Lean Leadership

Intelligent Manufacturing

How to Outthink, Outmaneuver, and Outperform Your Competitors

Reviving U.S. Manufacturing Including Lessons Learned from Delphi Packard Electric and General Motors

Lessons from the Masters of Strategy

R. Bick Lesser Examining the current U.S. manufacturing environment, including the unsustainable trade imbalance, this book outlines concrete suggestions that can help stop the outflow of manufacturing jobs and prosperity from our shores. The book explains why many companies have not reaped the benefits promised from the implementation of the multitude of improvement methodologies that have inundated manufacturers and outlines the steps companies can take to reverse this trend. The author's background in engineering and manufacturing, in both national and international assignments, puts him in a unique position to supply insights on foreign competition that few are able to provide.

• Explores why most companies have not reaped the promised benefits from the implementation of new manufacturing concepts that are currently popular and suggests steps that companies can take to reverse this trend

Norton Paley Supplying you with a firm grasp of the roots of strategy, this book explains how to develop the skills and strategies needed to compete in today’s volatile marketplace. It interweaves the classic works of the masters of strategy, such as Sun Tzu, Carl von Clausewitz, Mao Tse-tung, Niccolo Machiavelli, Frederick the Great, Napoleon, and other renowned strategists.

The collective insights of these legendary strategists span 2,500 of combative history and have survived meticulous analysis by scholars. Applied to current competitive business conditions, their time-tested rules and guidelines will prepare you to deal with such issues as: preventing competitors from disrupting your overall growth plans, protecting yourself from a rival’s take-over strategies, and strengthening longterm customer relationships.

• Covers several tools that the author developed and implemented in various manufacturing operations that have proven track records of improving performance significantly

Whether you operate as a multinational firm maneuvering for position in a global arena, or a regional business fighting an everyday battle for survival, the foundational principles provided can reinforce your understanding and practice of strategy. The book defines the historical origins of strategy and supplies timeless insight into how successful leaders have implemented comprehensive strategy plans. It also explains how to:

Selected Contents:

• Maneuver out of risky competitive situations and into renewed market opportunities

• Provides detailed information on how to effectively set up a manufacturing system and how to accurately measure and control direct labor

What Would You Expect with a Parent Like GM? We Have to Do Something, Even if It’s Wrong. How Does a Company with So Many Smart People Do So Many Dumb Things? Proper Manufacturing Organization Is Critical. When You Measure Performance, Performance Improves. Preplanning: The Perfect Tool to Accomplish Toyota’s Rule #1. The Computer Is a Moron. How to Drive Down Total Process Cycle Time without Wasting a Lot of Time (and Money). ...

Catalog no. K16020, September 2013, 332 pp.

Soft Cover ISBN: 978-1-4665-6404-6, $49.95 / £31.99

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• Establish a defensible position in a hotly contested market • Apply competitive business techniques to outperform your rivals • Align competitive strategies with your organization’s culture • Personalize a leadership style to maximize performance from your staff Catalog no. K16098, April 2013, 301 pp.

ISBN: 978-1-4665-6540-1, $49.95 / £31.99

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37

Lean Leadership

Strategic Planning, Execution, and Measurement (SPEM) A Powerful Tool for CEOs Girish P. Jakhotiya Based on decades of fieldtested experience, Strategic Planning, Execution, and Measurement (SPEM): A Powerful Tool for CEOs provides both a consultant’s view and an entrepreneurial approach to strategic planning, execution, and measurement. Walking you through the process, it begins by defining world-class status, visions, missions, business models, and value chains. Next, it discusses the two most important prerequisites of strategic planning and includes a questionnaire to help you evaluate operations, systems, and structure in your organization.

The book provides a matrix of 25 parameters for assessing the status of your organization that can help to pinpoint the perceptional gaps between top executives and owners. It includes a strategy bank with 150 generic strategies in the five performance areas of business and identifies methods for monitoring strategy execution that provide early warning signals. It also introduces the Entrepreneurial Score Card, a tool for improving the impact of strategic planning and execution in your organization.

Detailing the structure and preparation process for the strategic plan, the book illustrates the financial impact of strategy execution and explains the various financial monitoring parameters used in the performance cards of individual employees. It concludes by describing an entrepreneurial approach to strategic planning and with a comprehensive case study that illustrates the entire strategy formulation process and its conversion into an annual budget.

This book is ideal for CEOs, CFOs, COOs, business owners, heads of business verticals, heads of corporate planning or strategy, functional heads, teachers, students, and practicing consultants in the area of strategic planning.

Catalog no. K16335, May 2013, 293 pp., Soft Cover ISBN: 978-1-4665-6745-0, $69.95 / £44.99 Also available as an eBook

Maximizing Value Propositions to Increase Project Success Rates H. James Harrington and Brett Trusko “The best time to stop a project that will not add value to the organization is before it starts. An effectively prepared value proposition will help you make these difficult decisions.”

—Dr. Ron Skeddle, Former CEO of LOF, Inc., a Fortune 500 Glass, Plastics, and Hydraulics Company

In order to thrive in today’s increasingly competitive global environment, all sources of new and creative ideas within an organization must be considered.

Value propositions allow innovators, who may otherwise be intimidated to voice their ideas, to prepare a document that outlines the potential value of their ideas.

This book explains how to foster creativity in employees and encourage them to actively search for and document ideas that will add value to their organizations. Focusing on the necessary data collection efforts, it supplies readers with the understanding to create value propositions that separate profitable from unprofitable ideas.

• Identifies key opportunities that can add value to an organization • Focuses analysis on necessary data collection efforts • Provides direction and motivation for the improvement process • Details a method for continuous review of the improvement process • Encourages timeliness through digital-setting and milestones

Selected Contents: Importance of Value Propositions. The Opportunity Center: A New Approach to Capture Ideas and Concepts. The Value Proposition. Identifying New or Revised Product or Improvement Proposals.

Opportunity Analysis. Preparing the Value Proposition. Value Proposition Presentation.

Catalog no. K16501, April 2014, 220 pp., Soft Cover ISBN: 978-1-4665-7075-7, $29.95 / £18.99

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Lean Leadership

The Four Components of a Fast-Paced Organization

Beyond Lean Production Emphasizing Speed and Innovation to Beat the Competition

Going Beyond Lean Sigma Tools Robert Baird If you examine the characteristics of successful organizations, you will find that speed is a common denominator. Once there is a focus on speed, industry-leading improvements follow, momentum is created, and employees become further engaged to continue executing the strategy.

The Four Components of a Fast-Paced Organization: Going Beyond Lean Sigma Tools examines the components that must be in place for manufacturing and service organizations to achieve world-class business results at a rapid pace: leadership and mentoring, process design and visual value streams, organization structure for sustainment, and fast knowledge sharing.

The book illustrates the author’s experience working on a special Lean Sigma transformation at an organization going through a market alteration and having to consider outsourcing production to low-cost countries. It describes how the four key components helped the company achieve a doubling of productivity, a 75 percent improvement to its yield, and ontime delivery above 90 percent.

Outlining a simple, yet effective, implementation plan, the book supplies valuable guidance for Lean practitioners and organizational leaders on what needs to be done after Lean Sigma. It presents only the necessary information to allow you to dive right in to proven methods without having to waste time sorting through unnecessary details.

We all want a culture of continuous improvement, learning, and customer orientation; and this is what the four components can help you achieve. Follow the implementation steps outlined in the text and you will be on your way to developing and refining these characteristics.

Catalog no. K21486, November 2013, 228 pp.

ISBN: 978-1-4822-0600-5, $39.95 / £25.99

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Roger G. Lewandowski It is estimated that U.S. manufacturers are currently operating at only 65 percent effectiveness in implementing Lean production. Covering the fundamentals needed to be competitive in today’s marketplace, Beyond Lean Production: Emphasizing Speed and Innovation to Beat the Competition provides readers with the tools to help their organizations achieve 100 percent effectiveness in Lean production.

Explaining that overseas factories can't compete with U.S. factories in speed of delivery to domestic customers, the book provides the understanding required to add speed and urgency in all that you do in the office and the factory. It explains how to eliminate waste so you can meet and even exceed your customers’ expectations regarding service, quality, and cost.

The book is organized into two phases. The first phase, Holding Actions, covers the fundamentals needed to hold your position against the competition until you can implement the methods described in phase II of the book. It presents 12 little-known tools and strategic weapons that you can immediately put to use to improve on your current competitive position. Phase II, The Business Command Center, presents unique and powerful concepts that can be used with the fundamentals covered in phase I. Explaining how to use speed as a competitive weapon, the book will help you to remove the obstacles that interfere with continuous flow manufacturing. It presents the concept of circulatory management that can put a stop to the ever-increasing layers of management with decreasing ownership.

Catalog no. K22025, February 2014, 108 pp.

Soft Cover ISBN: 978-1-4822-1582-3, $29.95 / £25.99

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39

Lean Leadership

Leadership Basics for Frontline Managers

Leading the Lean Enterprise Transformation

Tips for Raising Your Level of Effectiveness and Communication

Second Edition

Bill Templeman Focused on interpersonal management skills, Leadership Basics for Frontline Managers: Tips for Raising Your Level of Effectiveness and Communication explains what it takes to improve how you communicate and relate to your employees, customers, and bosses. It presents 25 chapters grouped into four categories: Personal Effectiveness, Leadership, Communication, and Your Career. After reading this book, you will better understand: • How to deal with information overload • The best ways to manage during tough times • How to handle difficult co-workers • How to run more effective meetings • The basics of giving and receiving feedback • How to manage your career more effectively Each chapter dissects a different management skill and concludes with a list of bullet points to help you take action immediately. By illustrating key concepts with scenarios drawn from a range of work situations, this book is an ideal reference for: • Anyone new to a management position • Experienced managers who want to sharpen their leadership skills • Managers who find themselves managing a diverse group of employees Because the chapters were written to stand on their own, this book supplies guidance you can easily read in short chunks, a few minutes at a time. While the book draws on contemporary management theory, the bulk of the writing stems from the author's realworld experience as a facilitator, trainer, writer, coach, and program designer in both the private and public sectors.

Catalog no. K22179, March 2014, 151 pp.

Soft Cover ISBN: 978-1-4822-1995-1, $29.95 / £18.99

George Koenigsaecker Simpler Consulting, Inc., Ottumwa, Iowa, USA

Praise for the Bestselling First Edition: “Koenigsaecker has spent more time transforming more organizations into Lean enterprises than any other CEO. In this brief volume, he summarizes his 30 years of experimentation by describing Lean, showing how to measure it, explaining the role of value stream analysis and kaizen, and providing a tactical and a strategic action plan for Lean transformation.”

—Jim Womack, Chairman and Founder, Lean Enterprise Institute

Updated with new figures and new information, the second edition of this bestselling reference describes how the metrics used by Toyota drive every line item in a good direction. It explains the use of value stream analysis at the leadership level and demonstrates how to structure kaizen events that improve the value stream. Presenting tactical organizational steps to sustain improvements, it explores the development of a corporate assessment and review structure in support of a Lean transformation. The book introduces key leadership tools and discusses how to build a Lean culture.

• Provides additional information on tactical organization practices, strategy deployment, and Lean culture • Includes new and improved figures • Presents successful strategies of Lean leaders • Introduces cutting-edge leadership tools

Selected Contents: Introduction. My Journey of Lean Learning: Eleven Corporate Transformations. What Is Lean?

Measurement Can Be Easy. Value Stream Analysis Provides the Improvement Plan—And Kaizen Events Make It Happen. Tactical Organizational Practices.

Strategic Organizational Practices. Building a Lean Culture.

Catalog no. K12734, September 2012, 264 pp.

ISBN: 978-1-4398-5987-2, $52.95 / £33.99

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Lean Leadership

The Psychology of Lean Improvements

Toyota by Toyota Reflections from the Inside Leaders on the Techniques That Revolutionized the Industry

Why Organizations Must Overcome Resistance and Change the Culture

Samuel Obara Darril Wilburn

Chris A. Ortiz Kaizen Assembly, Bellingham, Washington, USA

San Antonio, Texas, USA

Winner of a 2013 Shingo Prize for Operational Excellence!

Fear of change—we all experience it. Some accept change immediately, some gradually adapt, while others may never get there. Whether it’s poor leadership, the inability to change, or pure ego, this Shingo Prize-winning book explores this perplexing commitment to inefficiency.

The Psychology of Lean Improvements examines the psychology behind why businesses avoid Lean transformations. It investigates why businesses cling to the eight deadly wastes and why they still find ways to place continuous improvement on the back burner.

Frequently sought out for his expertise in Lean manufacturing, Chris Ortiz has been featured in a number of trade publications and on the television show Inside Business with Fred Thompson. In this book, Mr. Ortiz breaks down the fear of change within executives and organizational leaders. He examines the psychology of dysfunction, provides insight into why so many businesses fall short in creating visions for growth and prosperity, and identifies tools that can help you address resistance to change.

Detailing implementation techniques with a proven track record for success, the book considers specific strategies that can be helpful towards improving your company and changing its culture—including cellular manufacturing, total productive maintenance, setup reduction, kanban, visual communication, and in-line production. It explains how to get started on your Lean transformation, describes why an economic downturn might be a good time to embrace Lean, and warns of the dangers behind failing to do so.

Catalog no. K13685, April 2012, 182 pp.

ISBN: 978-1-4398-7879-8, $41.95 / £26.99 Also available as an eBook

“What is our purpose? Addressed honestly, this hard question triggers the necessary reflection on shortcomings and weaknesses that are the fuel for improvement. It is a recurring theme in this volume. … Hansei, the Japanese word meaning humble and frank reflection, is another important concept in this book. ... This book records the reflections of several Toyota veterans—reflections on how they learned TPS and how they’ve applied the learning in companies around the world.”

—Pascal Dennis, Shingo Prize-Winning Author and President of Lean Pathways Inc.

Written by former Toyota associates, this book focuses on the purpose of Lean techniques, methodologies, and principles rather than the best way of applying tools. The contributors share their Toyota experiences and provide diverse points of view regarding the application of the principles discussed. Narrated by the author, who shares personal insights, each chapter describes a Lean technique, its benefits, its pitfalls, and supplies helpful tips on how to implement that technique.

• Presents first-hand accounts of former Toyota associates • Supplies various points of view regarding the application of basic TPS/Lean principles • Focuses on the purpose of Lean techniques and principles, instead of the best way of applying tools • Illustrates real-life experiences and examples

Selected Contents: Courage, Humility, Kaizen. Stability and Standardized Work. Jidoka. Just-In-Time and Kanban. ProblemSolving PDCA. Kaizen Culture: The Continuous Improvement Engine. Elimination of Waste in Product Design. Adapting Lean for Made-toOrder/High-Mix, Low-Volume Organizations. Lean Logistics. Leading a Kaizen Culture. Hoshin Kanri.

Catalog no. K13796, April 2012, 240 pp.

ISBN: 978-1-4398-8075-3, $41.95 / £26.99 Also available as an eBook

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41

Lean Leadership

The Controller as Lean Leader A Novel on Changing Behavior with a Lean Cost Management System

Also available as an eBook

The Right Choice

Using Theory of Constraints for Effective Leadership Ted Hutchin I & J Munn Limited, Leicestershire, UK

Sue Elizabeth Sondergelt Lean Beans, LLC, Cape Haze, Florida, USA

The Controller as Lean Leader delineates the differences between cost accounting and cost management. It uses a story format to present a compilation of experiences; some good, some bad, and some humorous. The story follows a fictional manufacturing entity embarking on a Lean change management journey for the second time—having failed at its first attempt at Lean implementation a few years earlier. As the story progresses, readers gain an understanding of what the company will do differently this time around to ensure it doesn’t slip backward again as the transformation unfolds.

• Illustrates the various approaches to Lean implementation • Explains Target Costing and describes how to use it to get your budget right the first time around

The need for competent leadership remains one of the most pressing issues facing organizations. Introducing a powerful technique to help readers become better decision makers, The Right Choice: Using Theory of Constraints for Effective Leadership supplies the understanding required to manage effectively well into the future through the use of the coaching cycle and the reflection process.

Using case studies, the book explains how to create a leadership culture at the organizational, team, and individual levels through the development of the flight crew, as well as how to link that to effective strategies and tactics in leading the organization forward. The case studies illustrate what leaders have actually done, what they’ve struggled with, and the importance of understanding causal relationships.

• Describes what the purpose of a Lean Human Resources (HR) system should be

Emphasizing the importance of consequences when making choices, the book reflects the author's vast experience with companies across a range of industries. It explains how to resolve conflicts and restore relationships through the use of time-tested tools, in particular, the cloud technique from the Theory of Constraints Thinking Processes.

• Introduces, with visuals, the little-known importance of the timing of the implementation and integration of the four integral parts of the Lean Cost Management System with the five Lean principles

The book details a practical methodology that you can use in various situations. Through the use of the coaching cycle and the coaching quadrant, it provides a solid platform for any leader wishing to take their organization forward.

The main character, the Lean Controller, presents her ideas with visuals throughout the book. Discussions between the Lean Controller and employees at various levels of the organization illustrate valuable lessons. The many faces of the Lean Controller as expressed through the many examples and stories provide you with the vision and tools to instill the desire to make a difference in workers across your entire organization.

Catalog no. K14016, May 2012, 176 pp.

ISBN: 978-1-4398-8621-2, $52.95 / £33.99

• Examines the concept of systems and the importance of defining values in your business

Catalog no. K13899, May 2012, 159 pp., Soft Cover ISBN: 978-1-4398-8277-1, $41.95 / £26.99

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Lean Leadership

Amoeba Management

Also available as an eBook

Lean Management System LMS:2012

The Dynamic Management System for Rapid Market Response

A Framework for Continual Lean Improvement

Kazuo Inamori

William A. Levinson Levinson Productivity Systems, Wilkes-Barre, Pennsylvania, USA

The synergy of the human and technological aspects of Lean form what Henry Ford called a universal code for achieving world-class results in any enterprise. This book expands upon and systemizes this universal code into a structure or framework that promotes organizational self-audits and continuous improvement.

The first section offers a foundation of four simple but comprehensive Lean key performance indicators (KPIs): waste of the time of things (as in cycle time), waste of the time of people, waste of energy, and waste of materials. The second section consists of an unofficial (and therefore customizable) standard against which the organization can audit its Lean management system.

• Provides examples and explanations of topics • Contains an appendix with ancillary material • Offers a foundation of four simple but comprehensive Lean key performance indicators • Outlines an unofficial and customizable standard (compatible with ISO 9001:2008) against which an organization can audit its Lean management system

Especially effective in dynamic and highly competitive environments, the Amoeba Management System has received attention from the Harvard Business Review and has been successfully adopted at hundreds of companies around the world. Written by the system's creator, this book provides a complete introduction to this unique and time-tested method of management control and accounting. Explaining the management philosophy and principles, it unveils fresh insights on how to foster a culture of leadership and responsibility in your organization.

Catalog no. K14727, August 2012, 164 pp.

ISBN: 978-1-4665-0949-8, $52.95 / £33.99 Also available as an eBook

The Future of Lean Sigma Thinking in a Changing Business Environment David Rogers

Selected Contents:

Danercon Limited, Harrow, UK

Why LMS: 2012? Overview. The Need for a Lean Management Standard. Lean Key Performance Indicators. Integrated Lean Assessment. LMS: 2012.

Lean Management System Requirements.

Organizational Responsibility. Lean System Infrastructure and Resources. Product or Service Realization. Measurement and Continual Improvement. Details and Expanded Explanation.

Lean Management System (4): Details.

Organizational Responsibility (5): Details.

Infrastructure and Resources (6): Details. Product or Service Realization (7): Details. Measurement and Continual Improvement (8): Details. Additional Lean Environmental and Energy Practices.

Supplying Lean practitioners with a formal process for keeping up with technological advances and shifting business requirements, this book provides the tools to survive and prosper through the current business environment. It introduces cutting-edge business solutions from the fields of chemical engineering, aircraft production, and business psychology—explaining how to integrate them with proven Lean principles. After providing a foundation in essential Lean concepts, the text reports on the latest advances in process understanding. It illustrates how new products are being developed using updated Lean thinking and also demonstrates the impact of e-commerce on Lean production systems.

Catalog no. K14563, August 2012, 215 pp.

Soft Cover ISBN: 978-1-4665-0537-7, $41.95 / £26.99 Also available as an eBook

Catalog no. K12329, June 2011, 216 pp.

ISBN: 978-1-4398-5102-9, $43.95 / £28.99

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Lean Leadership

Staying Lean

It's About Time

Thriving, Not Just Surviving, Second Edition

The Competitive Advantage of Quick Response Manufacturing

Peter Hines, Pauline Found, Gary Griffiths, and Richard Harrison The first edition of this highly acclaimed publication received a Shingo Research and Professional Publication Prize in 2009. Explaining how to create and sustain a Lean business, it followed Cogent Power’s first two Lean Roadmaps along their journey.

Since then, much has changed. Several members of Cogent Power’s senior management have moved on, steel prices have declined, and the credit crisis has sparked an unstable global economy. Set against these developments, this second edition reports on Cogent Power’s response to these issues—detailing how they worked through their third Lean Roadmap.

Catalog no. K11258, January 2011, 282 pp.

Soft Cover ISBN: 978-1-4398-2617-1, $43.95 / £28.99 Also available as an eBook

The 12 Principles of Manufacturing Excellence A Leader's Guide to Achieving and Sustaining Excellence Larry E. Fast Pathways to Manufacturing Excellence LLC

Explaining how to implement and sustain a top-down strategy for manufacturing excellence, this book provides a proven approach for delivering world-class performance while cultivating the right culture through leadership and mentoring. It describes how to achieve vertical and horizontal alignment across your organization and details the pathway to excellence via the 12 Principles of Manufacturing Excellence. It provides a method for tracking progress and includes a CD with color versions of the images in the text as well as a sample Manufacturing Excellence Audit, a sample Communications Plan, and a sample Training Plan.

Catalog no. K13535, October 2011, 266 pp.

ISBN: 978-1-4398-7604-6, $43.95 / £28.99 Also available as an eBook

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Rajan Suri Founding Director, Center for Quick Response Manufacturing, Madison, Wisconsin, USA

Presenting the developments in QRM since the publication of Rajan Suri’s landmark text, Quick Response Manufacturing, this book illustrates how QRM can not only reduce lead times but also improve quality, reduce operating costs, and enable companies to gain a substantial market share. It explains how factories in advanced nations can use QRM strategy to compete with manufacturers in low-wage countries and provides helpful pointers for QRM implementation, including accounting strategies, novel cost-justification approaches, and a stepwise process for implementation. It also includes a CD with time-saving tips to help you work through implementation issues.

Catalog no. K10299, March 2010, 228 pp.

ISBN: 978-1-4398-0595-4, $45.95 / £29.99 Also available as an eBook

The A3 Workbook Unlock Your Problem-Solving Mind Daniel D. Matthews Manufacturing Extension Partnership, National Institute of Standards and Technology

Facilitating participation and responsibility across an entire organization, this one-of-a-kind workbook takes readers step by step through the disciplined development of an A3 report, a single-sided piece of paper used by Lean companies to promote efficiency. The A3 provides all employees at all levels with a method to quickly identify a problem, analyze its root cause, select appropriate countermeasures, and communicate necessary actions to decision makers. The workbook includes worksheet templates that can be reproduced and used in future problem-solving efforts.

Catalog no. K11572, October 2010, 183 pp.

Soft Cover ISBN: 978-1-4398-3489-3, $57.95 / £36.99 Also available as an eBook

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Lean Metrics & Finance

The Performance Mapping and Measurement Handbook

The Lean CFO Architect of the Lean Management System Nicholas S. Katko Brian Maskell Associates, Inc.

Jerry L. Harbour Vector Resources, Inc., Trinidad, Colorado, USA

To better understand and improve your systems, you must measure and map their essential characteristics.

Yet, because your systems and their associated processes occur over varying spatial and temporal scales, you will need various types of maps and metrics—depending on the level of detail and understanding required.

During nearly four decades of experience helping clients across various industries understand, measure, and improve the performance of their processes, Jerry L. Harbour discovered a handful of performance maps that will work in most settings. As such, he's gathered these critical few maps into The Performance Mapping and Measurement Handbook.

In this handbook, Dr. Harbour explains performance mapping and measurement techniques at widely differing spatial and temporal scales. Using real-world examples and language that is easy to understand, he demonstrates the effective use of: • Node-link maps

Explaining why the CFO role is so critical for companies adopting a Lean business strategy, The Lean CFO: Architect of the Lean Management System illustrates the process of building and integrating a Lean management system into the overall Lean business strategy. It describes why CFOs should move their companies away from performance measures based on traditional manufacturing practices and into a Lean performance measurement system. In addition, it explains how to integrate a Lean management system with a Lean business strategy to drive financial success.

• Describes the logic behind why a Lean management system must replace a traditional management accounting system • Discusses how flow can drive the financial success of Lean • Demonstrates the need for constructing a value stream capacity measurement system • Explains how to break your company away from using standard costing to run your business The book explains why you must move your company into value stream accounting, which reports your internal financial information by the real profit centers of your business, your value streams. It describes the strategic aspects of making money from a Lean business strategy and also details how to modify your enterprise resource planning system to support Lean rather than hinder it.

• Process activity maps • Process step maps • Basic task element maps • Event pathway maps • Response timeline maps • Key performance driver maps Filled with graphical illustrations, the book can be read sequentially or used as a "How do I do that?" reference book. It includes easy-to-follow explanations along with numerous examples of both good and bad implementation. In addition, it includes case studies from a wide range of operational and industrial settings that clearly demonstrate how the mapping and measurement techniques described in the book can be applied to new technologies and processes.

Selected Contents:

Catalog no. K16536, March 2013, 185 pp.

Soft Cover ISBN: 978-1-4665-7134-1, $39.95 / £25.99 Also available as an eBook

Catalog no. K20946, September 2013, 151 pp.

ISBN: 978-1-4665-9940-6, $39.95 / £25.99

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The Architect. The Economics of Lean. $how Me the Value Stream Flow. $how Me the Office Flow.

Measure Lean Performance, Not Profits. It’s about Spending, Not Costs. The Value of Measuring Capacity. Decisions, Decisions, Decisions. Standard Costing Debunked. Tame the ERP Beast. By the People, for the People.

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45

Lean Metrics & Finance

Accounting in the Lean Enterprise

Beyond the Days of the Giants

Providing Simple, Practical, and Decision-Relevant Information

Solving the Crisis of Growth and Succession in Today's CPA Firms

Gloria McVay, Frances Kennedy, and Rosemary Fullerton

Paul D. Fisher

“McVay, Kennedy, and Fullerton marshal up a long needed instructional book, closing a significant gap in the ‘why’ and ‘how’ of applying Lean accounting as a cornerstone for a successful Lean journey.

Accounting in the Lean Enterprise: Providing Simple, Practical, and Decision-Relevant Information should be used by companies and universities alike to bridge this informational gap and give our future accountants and leaders required knowledge on managing financial, operational, and strategic decisions for our business organizations.”

—Jim Huntzinger, Founder and President of the Lean Accounting Summit

Winner of a Shingo Research and Professional Publication Award Accounting in the Lean Enterprise: Providing Simple, Practical, and Decision-Relevant Information explains how to develop the information and financial reports that serve the needs of a Leanminded business. It presents alternative methods of reporting, and includes a step-by-step guide for transitioning to Lean accounting methods.

Walking you through Lean tools, activities, and philosophies, it addresses some of the most often asked questions about Lean implementations. It confronts many of the fears that are the source of accountants’ resistance to change—including inventory management and valuation, GAAP compliance, and loss of control and benchmarks. Each fear is identified and resolved in a "Fear Box" inset, as the related topic is discussed.

Filled with checklists, guidelines, exercises, case studies, real-world examples, and company stories, the book provides you with the tools you will need to provide relevant, timely, and actionable information to the decision makers in your Lean environment.

Catalog no. PP8580, May 2013, 196 pp., Soft Cover ISBN: 978-1-4200-8858-8, $44.95 / £28.99

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KDV, Ltd.

Check out what these Accounting Today Top 100 Most Influential People in the Accounting Profession have to say about the book: “This is the first book that provides CPA firms with a plan for getting the next generation of accountants engaged. Paul offers an insightful view of what is ailing accounting firms today—a value-creation problem—and sets a new standard of client care that starts with engagement, transparency, and relevance as well as providing clients with effective choices.”

—August Aquila, CEO Aquila Global Advisors

“An ambitious and thought-provoking work that expertly weaves growth, succession, innovation, and value creation—Paul Fisher and I share a common vision of the accounting profession’s growth challenges and choices.”

—Gale Crosley, Founder, Crosley+Company

“Paul Fisher cuts through the generational clashes inside CPA firms as he addresses the drastic changes in the profession. If you want your firm to survive in a new era—buy this book, dog ear its pages, and make it required reading for all employees.”

—Rebecca Ryan, Founder, Next Generation Consulting

During the next decade, nearly half of all public accounting firm partners will retire. This exodus will put an enormous intellectual and financial drain on firms. This book provides an implementation guide for accounting firms during this next critical decade. It supplies step-by-step guidance on how to document an organizational culture, how to prepare production systems to build and operate value management systems, and how to re-orient practitioners on the valuecreation practice.

Catalog no. K21321, September 2013, 181 pp.

Soft Cover ISBN: 978-1-4822-0356-1, $39.95 / £25.99

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Lean Metrics & Finance

The Right Measures

The Basics of Performance Measurement

The Story of a Company’s Journey to Find the True Indicators of Its Success and Values

Second Edition Jerry L. Harbour Battelle, Albuquerque, New Mexico, USA

Mark A. Nash Pelco Products, Edmond, Oklahoma, USA

Sheila R. Poling Pinnacle Partners, Inc., Oak Ridge, Tennessee, USA

This book follows the story of two companies—one that measures in great detail, yet its overall goals and objectives are not being achieved. While the other uses a much simpler, yet effective measurement structure that integrates cultural acceptance, individual performance, and team performance with key performance indicators. Illustrating how measures can impact employee behavior, profitability, and customer satisfaction, the text provides the understanding required to select the appropriate measures for your organization.

Catalog no. K13677, August 2012, 223 pp.

Soft Cover ISBN: 978-1-4398-7865-1, $52.95 / £33.99 Also available as an eBook

Second Edition The Accountant as Change Agent on the World-Class Team

A Proven System for Measuring and Managing the Lean Enterprise, Second Edition

Brian H. Maskell

Brian H. Maskell, Bruce Baggaley, and Larry Grasso

Brian Maskell Associates, Inc., Cherry Hill, New Jersey, USA

The methods and concepts presented in the bestselling first edition revolutionized the approach to the management and control of Lean companies.

Enhanced with extensive end-of-chapter exercises and a CD-ROM with Lean accounting tools, the second edition of this preeminent practitioner’s guide is now suitable for classroom use. This edition explains what it takes to transform a traditional accounting system to one that supports and enhances a company’s Lean efforts. Defining the fundamental principles of Lean accounting, it demonstrates how to use them to identify and eliminate wasteful transactions.

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Catalog no. K10132, June 2009, 102 pp., Soft Cover ISBN: 978-1-4398-0249-6, $18.95 / £13.99

Making the Numbers Count

Practical Lean Accounting

Catalog no. K10889, August 2011, 475 pp.

Soft Cover ISBN: 978-1-4398-1716-2, $65.95 / £42.99

Originally published in 1997, The Basics of Performance Measurement helped pioneer the science of performance measurement and continues to serve as an industry standard. Yet, despite the book’s continued relevancy, Harbour is once again stepping ahead of the curve to fully update his little yellow book. In addition to adding the wisdom of lessons learned over the past decade, he adds two new chapters to this second edition. One of these chapters discusses units of measurement. The other introduces ways to better interpret what has been measured and then translate those measurement-related interpretations into actionable knowledge.

A delineation of the changes required for accounting, control, and measurement methods in Lean organizations, this book challenges readers to take a fresh look at their accounting systems. It clarifies methods for innovative, proactive management accounting and presents techniques for simplifying accounting systems so that they serve production, marketing, and engineering sectors with equal efficiency. Updated to include current principles, practices, and tools of Lean accounting, the second edition uses the same polemical style that made the first edition so popular. It covers ABC, VAM, performance measurement, concurrent engineering, target costing, value engineering, and life cycle costing.

Catalog no. PP0607, June 2009, 243 pp.

ISBN: 978-1-4200-9060-4, $45.95 / £29.99

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Lean Office

Making IT Lean Applying Lean Practices to the Work of IT Howard Williams and Rebecca Duray Making IT Lean: Applying Lean Practices to the Work of IT presents Lean concepts and techniques for improving processes and eliminating waste in IT operations and IT Service Management, in a manner that is easy to understand.

The authors provide a context for discussing several areas of application within this domain, allowing you to quickly gain insight into IT processes and Lean principles.

The text reviews IT Service Management, with reference to the IT Infrastructure Library (ITIL®) as a framework for best practices—explaining how to use it to accommodate Lean processes and operations. Filled with straightforward examples, it provides enough modeling tools so you can start your Lean journey right away.

Throughout the book, the authors use a simple model for Lean Improvement as the framework for communicating practical guidance on identifying and understanding problems, as well as identifying, implementing, managing, and improving solutions. Emphasizing alignment with core Lean concepts, such as A3 Thinking and Plan Do Check Act, it introduces concepts in a manner that allows you to take away small bits at a time and immediately apply them in your IT operations. Exploring the notion that any IT organization can benefit from the application of Lean, the text supplies you with virtually limitless opportunities for improvement in your IT organization.

Selected Contents: The Scope of IT. IT Operations and Operations Management. A Brief History of Lean. Lean and IT. ITIL (IT Infrastructure Library). IT for Lean. Lean for IT. Lean IT Operations Management. Lean IT Service Management. Lean and ITIL. Catalog no. K13533, November 2012, 232 pp.

Soft Cover ISBN: 978-1-4398-7602-2, $62.95 / £40.99 Also available as an eBook

Metrics-Based Process Mapping Identifying and Eliminating Waste in Office and Service Processes Karen Martin Karen Martin & Associates, San Diego, California, USA

Mike Osterling Osterling Consulting, La Mesa, California, USA

Building on the success of its popular predecessor, Metrics-Based Process Mapping: An Excel-Based Solution, this book takes readers to the next level in understanding processes and process improvement.

Included with the book is an interactive macro-driven Excel tool, which allows users to electronically capture their current and future state maps. The tool also audits the maps for completeness, summarizes the metrics, and auto-calculates the improvements.

Improvements to this version include: • Foundational content about processes—what they are and how they vary • Tips for effective team formation and mapping facilitation • An implementation plan for those using the mapping methodology as a standalone tool and not part of a Kaizen Event The Excel-based tool included on the accompanying CD provides readers with a user-friendly way to electronically archive manually created maps in team settings for easier storage and distribution across your entire organization. While current and future state MBPMs are initially created during team-based activities using butcher paper and post-its, the electronic maps serve as standard work documentation for the improved process, enabling training, communication, and process monitoring activities.

This flexible, user-friendly tool includes: • A custom toolbar that simplifies map creation and editing • Automated calculation of key metrics • An audit feature to prevent mapping errors • The ability to simulate how improvements will impact staffing requirements System Requirements: The tool is intended for use on PCs using Excel 2003 or later—it will NOT function with earlier versions of Excel, or on Macintosh computers.

View a demo of the Excel tool at: www.mbpmapping.com Catalog no. K14024, October 2012, 116 pp.

Soft Cover ISBN: 978-1-4398-8668-7, $104.95 / £66.99

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Lean Office

Gemba Walks for Service Excellence

Run Grow Transform Integrating Business and Lean IT

The Step-by-Step Guide for Identifying Service Delighters

Steven Bell

Robert Petruska Gemba Walks for Service Excellence: The Step-byStep Guide for Identifying Service Delighters guides readers on a journey towards organizational effectiveness that supports a culture of service excellence. It provides a fresh perspective on how to apply Gemba Walks—visiting the areas where the service provider interacts directly with the customer—to identify new service delighters and make a lasting positive impression on customers.

Using an abundance of color pictures and handdrawn graphics, Robert Petruska builds on his considerable experience implementing Lean and quality systems to demonstrate how to create the infrastructure required for service excellence to flourish. Presented in an easy-to-follow format that anyone in the service industry can enjoy, this workbook: • Shares proven techniques used in Lean manufacturing that can easily be applied to the service industry • Guides new employees and veterans alike through a journey filled with real-life stories that inspire confidence • Contains hands-on exercises that allow you to immediately apply the ideas to your own work • Includes a CD with innovative "placemats" designed to provide stepping stones on a development path for your team to achieve a competitive advantage Filled with real-world examples and stories of service excellence, the book will help you develop the counterintuitive thinking needed to discover new sources of customer delight. Designed to be used with your entire team, this workbook will guide your organization, step by step, through a plan for assessing, prioritizing, and implementing innovative ideas that will lead to unprecedented levels of service excellence.

Catalog no. K14025, June 2012, 99 pp., Soft Cover ISBN: 978-1-4398-8674-8, $41.95 / £26.99

“Run Grow Transform takes the next logical step to driving enterprise value.

This could be the gamechanging playbook for IT 3.0.”

—Mark Katz, CIO & Senior Vice President, Esselte Corporation

“This book focuses on the most critical and challenging issue for any aspect of the development or use of IT: creating a collaborative learning culture.”

—Jeffrey K. Liker, Shingo Prize-Winning Author of The Toyota Way

“Run Grow Transform clarifies the eternal quest of IT: to simply "running" of the business and to create innovative solutions to grow the business and create sustainable competitive advantage to transform the way customers interact with your business, in plain, actionable advice from one who has been on the front lines.”

—Tom Foco, Value Stream Solutions

Your customers want innovation and value, and they want it now. How can you apply Lean principles and practices throughout your enterprise to drive operational excellence, reduce costs while improving quality, enable efficient growth, and accelerate idea-tovalue innovation? Shingo Prize-winning author Steve Bell and other thought leaders show you how—guiding you to more effectively align people and purpose, promote enterprise agility, and leverage transformative IT capabilities to create market-differentiating value for your customers.

Features: • Presents the insights of a Shingo Prize-winning author, subject matter experts, and thought leaders of the Lean IT community • Outlines a framework to facilitate collaboration and stimulate innovation • Supplies a collaborative value stream management approach for harnessing Lean principles and practices across the entire enterprise Catalog no. K14527, September 2012, 372 pp.

Soft Cover ISBN: 978-1-4665-0449-3, $52.95 / £33.99 Also available as an eBook

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49

Lean Office

Lean Office and Service Simplified

Lean Human Resources

The Definitive HowTo Guide Drew Locher Change Management Associates, Mt. Laurel, New Jersey, USA

Winner of a Shingo Research and Professional Publication Award “… a simple guide to help leaders drive the Lean transformation of themselves, their people, and processes.”

—Glenn Marshall, Northrop Grumman Shipbuilding

“Drew is still one of the few practitioners who really understand the concept of the Lean Enterprise as opposed to Lean Manufacturing.”

—Bill Beer, Wenger Corporation

“... a plain language guide to transforming office and service industries into effective, efficient organizations. I recommend it strongly.”

—Mike Robinson, Manager, Corning Cable Systems

“… Locher’s book delivers! Every essential tool in the Lean toolkit is explored with enough simplicity for a beginner to understand and enough depth for an experienced Lean thinker to draw from.”

—Allan R. Coletta, Siemens Healthcare Diagnostics, Inc.

Demystifying the application of Lean methods, this Shingo Prize winner details the key concepts of Lean as they apply to office and service environments. It discusses value stream management, standard work, flow, level pull, and visual management. The text breaks down Lean concepts into their elementary components, describes them in a nonmanufacturing context, and supplies specific how-to methodologies.

It includes a toolbox of helpful forms, charts, checklists, templates, and worksheets to kick-start Lean implementation efforts.

Selected Contents: Organizing by Value Stream. Creating Standard Work for Office and Service. Creating Flow in Office and Services. Creating Level Pull in the Office.

Establishing Visual Management in Office and Services. Lean Tools for Office and Services.

Functional Applications of Lean. Leading the Lean Organization. Quality Toolbox. Forms.

Redesigning HR Processes for a Culture of Continuous Improvement Cheryl M. Jekiel Flying Food Group, USA

“Jekiel makes a strong case for the greater part of waste coming from poor or nonexistent HR systems; she breaks down that complex subject into root causes, commentary, and then solutions. Her systematic mapping of the path to get out of the cave and into the light of day gives the reader hope that transformation of the culture is possible.”

—Sherrie Ford, Chairman of the Board and Executive VicePresident, Culture Power Partners, Inc.

Encouraging a long overdue shift in thinking, this book gives managers and CEO's the means to maximize employee potential by first showing them how to increase the improvement power of their HR departments. Jekiel, who has been implementing Lean initiatives out of HR offices for 20 years, defines the people-related approaches needed to alter cultural dynamics. She looks at why so many companies allow this waste to exist and how traditional HR has not been especially effective in combating waste.

• Shows how HR must be utilized to initiate the cultural dynamics needed to make real and lasting improvement • Provides a proven five-year plan for implementing and monitoring quality improvements • Offers the guidance of a career HR leader who has overseen a variety of Lean initiatives

Selected Contents: Why You Should Read This Book Now. A Background in Business, Lean, and HR. Involving HR as a Business Partner. How HR Can Influence and Change Work Cultures. Redesign Roles for Better Results. Strategies for Aligning Your HR Processes. Especially for CEOs. Catalog no. K10663, September 2010, 263 pp.

Soft Cover ISBN: 978-1-4398-1306-5, $45.95 / £29.99 Also available as an eBook

Catalog no. K11073, February 2011, 194 pp.

Soft Cover ISBN: 978-1-4398-2031-5, $43.95 / £28.99

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Product Development

The Basics of Project Evaluation and Lessons Learned

Design for Manufacturability

Second Edition Willis H. Thomas Pfizer/Wyeth Research, Montvale, New Jersey, USA

The first edition won the Project Management Institute's (PMI®) David I. Cleland Project Management Literature Award. Following in the footsteps of its popular predecessor, this second edition provides an easy-to-follow, systematic approach to conducting lessons learned on a project.

The research in this book is founded on four years of doctoral dissertation research and is supported by renowned experts in the field of evaluation. The concepts covered are applicable to all types of organizations that implement projects and need to conduct lessons learned.

• Presents new information that updates the first edition that won the Project Management Institute's (PMI®) David I. Cleland Project Management Literature Award • Reinforces the project standards as outlined in the Project Management Body of Knowledge (PMBOK® Guide) published by PMI® • Supplies the insights of an author that consults internationally with many pharmaceutical companies • Provides an easy-to-follow, systematic approach to conducting lessons learned on a project

Selected Contents: Project Management Overview. Foundations of Evaluation. Origins of Lessons Learned in Project Management. Challenges with Lessons Learned.

Lessons Learned Tools and Techniques. Best Practices and Benchmarking. Lessons Learned Case Studies.

Real Life Lessons Learned Scenarios. Advancing Lessons Learned through Evaluation. Implementing a Lessons Learned System.

Catalog no. K21381, September 2014, 176 pp.

Soft Cover ISBN: 978-1-4822-0453-7, $24.95 / £14.99

How to Use Concurrent Engineering to Rapidly Develop Low-Cost, HighQuality Products for Lean Production David M. Anderson This book shows how to use concurrent engineering teams to design products for all aspects of manufacturing with the lowest cost, the highest quality, and the quickest time to stable production. Extending the concepts of design for manufacturability to an advanced product development model, the book explains how to simultaneously make major improvements in all these product development goals, while enabling effective implementation of Lean Production and quality programs.

Illustrating how to make the most of lessons learned from previous projects, the book proposes numerous improvements to current product development practices, education, and management. It outlines effective procedures to standardize parts and materials, save time and money with off-the-shelf parts, and implement a standardization program.

• Describes how to design families of products for Lean Production, build-to-order, and mass customization • Emphasizes the importance of quantifying all product and overhead costs and then provides easy ways to quantify total cost • Details dozens of design guidelines for product design, including assembly, fastening, test, repair, and maintenance • Presents numerous design guidelines for designing parts for manufacturability • Shows how to design in quality and reliability with many quality guidelines and sections on mistake-proofing (poka-yoke) Describing how to design parts for optimal manufacturability and compatibility with factory processes, the book provides a big picture perspective that emphasizes designing for the lowest total cost and time to stable production.

Catalog no. K21414, February 2014, 486 pp.

ISBN: 978-1-4822-0492-6, $59.95 / £38.99

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51

Product Development

Methods in Product Design

Creating a Lean R&D System

New Strategies in Reengineering

Lean Principles and Approaches for Pharmaceutical and Research-Based Organizations

Edited by

Ali K. Kamrani, Maryam Azimi, and Abdulrahman M. Al-Ahmari Customer-focused product design strives to meet changing customer requirements with new product features. This book discusses ways to assess changing demands and sources, and delves into what is needed to successfully manufacture goods in a demanding market. It reviews proven methods for assessing customer need. Then, after showing how changing needs impact the reengineering of products, it explains how needed change can be efficiently achieved. It details how IT advances and technology support customerfocused product development, discusses cutting-edge mass customization principles that maximize costeffective production, and illustrates how to implement a web-based product design environment.

• Demonstrates successful methods of sustainable design • Examines how changing customer needs impact the reengineering of products and how this is accomplished in a timely, efficient, and costeffective manner • Details how advances in information systems and technology support customer-focused product development • Discusses cutting-edge mass customization principles to maximize cost-effective production of new and reengineered goods • Illustrates how to implement effective maintenance policies

Selected Contents: Sustainable Design. Cellular Manufacturing Systems.

An Overview of Computer-Aided Design. Selection of Parameters for CAD-VR Data Translation. A SemiIntegration System of CAD and Inspection Planning of Standard Manufactured Features. Tumor Geometrical Deformation Modeling. Product Variety and Manufacturing Complexity. A Simulation-Based Methodology for Manufacturing Complexity Analysis. Optimizing Supply Chain Network Design.

Shutdown Maintenance Scope of Work Assessment Mode: Model for Reducing Shutdown Maintenance Costs and the Loss of Production at Continuous Process Industries. Machine Failure Time Detection through Product Defects.

Terence M Barnhart Director, Development Operations, Sandoz Inc., East Hanover, New Jersey, USA

Creating a Lean R&D System lays out the logic of why Lean implementation isn’t strictly for manufacturing and describes why it can be just as effective in R&D organizations. Terence Barnhart, former senior director of continuous improvement at Pfizer R&D, describes the theoretical and physical underpinnings of creating a Lean transformation in any R&D organization, as exemplified by the Lean transformation initiated within the R&D division of a global pharmaceutical company.

Describing how to merge Lean principles with the cultural virtues inherent in R&D, the book presents Lean approaches that can be easily applied in pharmaceutical and research-based organizations. It takes a strategic approach to solving two problems unique to the Lean field. The first is in noting the key distinctions between R&D and manufacturing, and developing a Lean approach specific to the R&D environment. The second is that it proposes a systematic middle-out (merger/maneuver) strategy to help you initiate and sustain a Lean culture within your pharmaceutical R&D organization that will help you immediately engage all stakeholders involved.

Selected Contents: Seeing and Removing Barriers in the R&D Environment. Lean in Research and Development.

The Individual in the Lean R&D Community. Lean Exercises for the R&D Professional. The A3 in Developing R&D Thinking. The Lean R&D Manager.

Removing Barriers within the R&D Community.

Critical Question Mapping. Value Stream Mapping in the R&D Space. Implementation Strategy. The Formation of Lean R&D Communities: A Case Example. Reflections.

Catalog no. K10063, August 2012, 267 pp.

ISBN: 978-1-4398-0078-2, $52.95 / £33.99

Catalog no. K10411, May 2013, 340 pp.

ISBN: 978-1-4398-0832-0, $89.95 / £57.99 Also available as an eBook

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Product Development

The Mastery of Innovation

Unleashing the Power of 3P

A Field Guide to Lean Product Development

The Key to Breakthrough Improvement

Katherine Radeka

Dan McDonnell and Drew A. Locher Recent improvements at Enterride’s Trail Rider Memphis Operation bought Pete Grant, the Trail Rider plant manager, and his team a little more time, but Pete knew much more was needed to save the plant. They needed a breakthrough, a true game changer. Then someone told Pete about a process called 3P that could lead to unprecedented improvement when utilized during major change programs.

Could this be just what he was looking for?

Unleashing the Power of 3P: The Key to Breakthrough Improvement follows Pete and his team as they journey through Lean and the Production Preparation Process (3P). Using an easy-tofollow story, it allows readers to tag along as the team learns how to trim waste, increase efficiency, and bring their plant back from the brink. You’ll learn from the team’s mistakes and follow them as they visit a hospital and learn how Lean and 3P can be applied in any industry. A go-to guide for 3P execution, this book: • Details a proven methodology for successful implementation of corporate change programs • Presents information workbook format with real-world examples • Uses an engaging story to guide readers through a 3P project—from beginning to end The book outlines time-tested methods that can be applied to any combination of product, process, and facility design to reduce costly redesign iterations and associated delays. Based on a true story, it takes you on a journey as Enterride completes a new production start-up in dramatically reduced time and cost.

Watch co-author Drew Locher discuss how 3P can stop project delays and increase efficiency in your organization. http://www.youtube.com/watch?v=JWC88lPsW60&f eature=youtu.be Catalog no. K14013, October 2012, 182 pp.

Soft Cover ISBN: 978-1-4398-8612-0, $52.95 / £33.99 Also available as an eBook

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Whittier Consulting Group, Inc., Camas, Washington, USA

Winner of a Shingo Research and Professional Publication Award!

The Mastery of Innovation: A Field Guide to Lean Product Development describes the experiences of 19 companies that have achieved significant results from Lean Product Development. Their stories show that Lean Product Development delivers results: • Ford Motor Company completely reinvented its Global Product Development System and put decades of knowledge about automotive design at its engineers’ fingertips • DJO Global, a medical device company, more than tripled the number of products they released to the market and cut development time by 60 percent • Playworld Systems cut time-to-market in half The diverse set of North American and European case studies in this book range from very small product development organizations (three engineers) to very large (more than 10,000). Some of the industries represented include automotive, medical devices, industrial products, consumer electronics, pharmaceuticals, scientific instruments, and aerospace.

These companies have generously shared their knowledge about Lean Product Development to help you get your best ideas to market faster.

Selected Contents: Lean Product Development: The Mastery of Innovation. The Pioneers of Lean Product Development. Lean Product Development to Make The Right Products. Lean Product Development To Make Products Better, Faster, Cheaper. Lean Product Development Transformation. The Path of Innovation Mastery.

Catalog no. K13574, October 2012, 265 pp.

ISBN: 978-1-4398-7702-9, $52.95 / £33.99 Also available as an eBook

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Product Development

The Lean 3P Advantage

A Tale of Two Transformations

A Practitioner's Guide to the Production Preparation Process

Bringing Lean and Agile Software Development to Life

Allan R. Coletta

Michael K. Levine

Siemens Healthcare Diagnostics, Bear, Delaware, USA

Wells Fargo Home Mortgage, Minneapolis, Minnesota, USA

Winner of a Shingo Research and Professional Publication Award!

There are many books that seek to explain Lean and Agile software that offer theory, techniques, and examples. Michael Levine’s first book, A Tale of Two Systems, is one of the best, synthesizing Lean manufacturing and product development with Agile software concepts in an engaging business novel. However, there has been precious little practical guidance for those seeking to change existing organizations to become Lean and Agile, until now. Mr. Levine has followed the successful approach of A Tale of Two Systems, telling two simultaneous intertwined and contrasting stories, to bring organizational transformation to life.

“Finally, a go-to reference book on the important subject of 3P. Coletta does an outstanding job defining a step-by-step approach that can provide breakthrough results to manufacturing and service organizations alike.”

—Drew Locher, Managing Director, Change Management Associates

Written from an operations perspective, this Shingo Prize-winning book explains how to build collaborative thinking and innovation into the front end of the design process. Describing how to develop successful new products concurrently with new operations, the book illustrates real-world scenarios with numerous examples and case studies to help newcomers succeed the first time around. For those familiar with 3P, the book supplies the basis to explore Evergreen 3P— a process for applying 3P to small-scale design projects for similar benefits.

• Details the 3P Lean Design process sequentially • Provides examples of real-world applications • Explains how and why the process works • Presents an operations perspective based on the combined experience of numerous practicing companies

Selected Contents: 3P Lean Design Concepts. Applying 3P Lean Design and Gaining Leverage. Getting Started. The Countdown. Overview of the 3P Event Week. Kickoff, Charter, and 3P Goals. Process Evaluation Criteria, Defining Functions. Flow Diagrams, Developing Seven Alternatives and Selection of the Better Three Alternatives. Process at a Glance, Selecting Teams, Constructing the Three Prototypes.

Evaluating the Three Prototypes, Determining the Final Prototype. Developing the Final Prototype, Incorporating Evaluation Criteria and Measuring Effectiveness, Final Report-Out. 3P Project Development, Potholes and Stumbling Blocks.

Evergreen 3P Lean Design.

Mary O’Connell and James "Wes" Wesleyan, recently engaged to be married, share a commitment to Lean and Agile Software. They have recently become leaders in two very different companies—one, stuck in a slow-moving, unresponsive, process-driven quagmire of a software culture; the other, struggling through the chaos of a sales-driven, process-less swirl. Together with their wise mentor, Neville Roberts, they identify two approaches to making needed changes: Drive People (a top-down approach focused on processes and tools), and People Driven (an enablement approach focused on people and organizations).

Mary and Wes evaluate their situations and choose approaches that best fit for them, and the transformations commence.

A Tale of Two Transformations differs from many information technology books by grappling with all the complexities of our organizations: the people, the politics, the financials, the processes—in short, the culture from which our Lean and Agile journeys must begin. The change model presented in the flow of the stories is generally applicable, and can help anyone thinking about how to improve their organization.

Catalog no. K13742, December 2011, 323 pp.

ISBN: 978-1-4398-7975-7, $65.95 / £42.99 Also available as an eBook

Catalog no. K13706, March 2012, 336 pp.

Soft Cover ISBN: 978-1-4398-7911-5, $41.95 / £26.99 Also available as an eBook

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Value Stream Mapping

Creating Mixed Model Value Streams

Using Hoshin Kanri to Improve the Value Stream

Practical Lean Techniques for Building to Demand, Second Edition

Elizabeth A. Cudney Missouri University of Science and Technology, Rolla, USA

Kevin J. Duggan Duggan Associates, North Kingstown, Rhode Island, USA

Following in the footsteps of its bestselling predecessor, Creating Mixed Model Value Streams, Second Edition takes a step-by-step approach to implementing Lean in complex environments. It describes which Lean techniques to use when faced with difficult situations—including high product mix, scheduling problems, shared resources, and unstable customer demand.

In addition to a new section on handling shared resources to support mixed model production, the second edition: • Contains updates to sections on mixed model value streams • Introduces new information on constructing product family matrices • Expands on the concept of takt in mixed models • Provides insights on existing mixed model concepts • Presents new concepts on sequencing work Complete with a case study based on actual experience as well as a CD with helpful tools, the book walks readers through the reasoning the author has used with great success in practice. It delves beyond the basics of value stream mapping to explain how to create future states in a manufacturing environment characterized by multiple products, varying cycle times, and changing demand. Demonstrating advanced techniques for creating flow through shared resources, it also considers the concept of a guaranteed turnaround time for the shared resource.

The Accompanying CD Includes: • Spreadsheet and tutorial for sorting products into families • Spreadsheets for calculating equipment required and for determining the interval for Every Part Every Interval • Samples of visual method sheets for standard work • Case study value stream maps and mapping icons Catalog no. K13116, July 2012, 258 pp., Soft Cover ISBN: 978-1-4398-6843-0, $62.95 / £40.99

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“Every industrial engineer should purchase Using Hoshin Kanri to Improve the Value Stream. It provides the key to using the Hoshin Kanri framework and integrating it with the foundations of industrial engineering.”

— Marjorie Koch, President, Lean Division, Institute of Industrial Engineers

“Cudney's book provides a clear and concise view of how to best use Hoshin Kanri to drive improvement and realize the level of results organizations want and need. ... should be required reading for all business executives.”

— Karen Martin, Karen Martin & Associates, Author of The Kaizen Event Planner

While value stream mapping is now accepted as a tool for identifying waste, future state mapping presents greater challenges. Achieving the full implementation pictured in an enhanced future state map is far more complex than its development. Hoshin Kanri can help.

This method encourages employees to incorporate performance metrics to reach the root cause of problems before searching for solutions and teaches them how to promote the achievement of sustainable implementation. Though developed in Japan this technique is based on Deming’s classic Plan-DoCheck-Act improvement cycle.

• Uses the strategic long-term vision of the organization to prioritize continuous improvement efforts • Combines two distinct Lean tools—value stream mapping and Hoshin Kanri • Presents a unique and effective way of creating the future state of the value stream map

Selected Contents: Lean as a Competitive Strategy. Strategic Thinking.

Understanding Value Improve. Plan and Implement.

Conclusion. Leancyclopedia. Lean Glossary.

Additional Resources.

Catalog no. PP8423, March 2009, 160 pp.

Soft Cover ISBN: 978-1-4200-8423-8, $59.95 / £31.99 Also available as an eBook

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55

Six Sigma

Warranty Claims Reduction

The Lean Six Sigma Black Belt Handbook

A Modern Approach with Continuous Improvement Techniques

Tools and Methods for Process Acceleration

Ronald Blank Senior Quality Engineer and Productivity Consultant

Reduced market share, lack of repeat customers, and added costs are just a few ways warranty claims can hurt an organization. Avoiding complex mathematics or accounting terminology, this book explains how to boost profits through the reduction of warranty expenses in your organization.

Outlining a multifunctional approach for reducing claims, the book begins by summarizing the traditional and most common strategies for warranty cost reduction. Next, it explains how you can reduce warranty costs even further by taking a more complete approach. The comprehensive approach described arms you with less conventional, yet powerful, approaches for reducing warranty costs such as improving warranty processing productivity, clarifying installation and usage instructions, and streamlining supply chain management.

The book emphasizes the improvement of efficiencies and productivity in addition to cost reductions. It outlines methods that can help you reduce warranty costs, improve processing activity, reduce wasted time, and improve training of OEM and warranty service personnel. It also describes methods for providing feedback to those in the engineering, manufacturing, and quality control departments.

The text details methods that are fully compatible with ISO 9001 systems and its sector-specific variations, like AS 9100 and TS 16949. Covering concepts that are applicable across all industries and retail markets, it is an ideal reference for anyone involved in the management of warranty claims processing.

The multifaceted approach described in the book can help you achieve more cost reductions than are possible through conventional thinking.

Catalog no. K21621, June 2014, 181 pp.

ISBN: 978-1-4822-0912-9, $49.95 / £31.99

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Frank Voehl, H. James Harrington, Chuck Mignosa, and Rich Charron Although Lean and Six Sigma appear to be quite different, when used together they have shown to deliver unprecedented improvements to quality and profitability. The Lean Six Sigma Black Belt Handbook: Tools and Methods for Process Acceleration explains how to integrate these seemingly dissimilar approaches to increase production speed while decreasing variations and costs in your organization.

Presenting problem-solving tools you can use to immediately determine the sources of the problems in your organization, the book is based on a recent survey that analyzed Six Sigma tools to determine which are the most beneficial. Although it focuses on the most commonly used tools, it also includes coverage of those used a minimum of two times on every five Six Sigma projects.

Identifying the theories required to support a contemporary Lean system, the book describes the new skills and technologies that you need to master to be certified at the Lean Six Sigma Black Belt (LSSBB) level.

It also covers the advanced non-statistical and statistical tools that are new to the LSSBB body of knowledge.

Selected Contents: Introduction to Lean Six Sigma Methodology.

Process Improvement and Lean Six Sigma. The Lean Journey into Process Improvement. Waste Identification. Lean Concepts, Tools, and Methods.

Three Faces of Change—Kaizen, Kaikaku, and Kakushin. SSBB Overview. On Integrating LSS and DMAIC with DMADV. LSSBB Advanced Nonstatistical Tools. Black Belt Nonstatistical Tools. LSSBB Advanced Statistical Tools. Advanced Statistical Tools.

Catalog no. K15330, July 2013, 621 pp.

ISBN: 978-1-4665-5468-9, $59.95 / £38.99 Also available as an eBook

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Six Sigma

Building Quality Management Systems

Baldrige Award Winning Quality

Selecting the Right Methods and Tools

18th Edition How to Interpret the Baldrige Criteria for Performance Excellence

Luis Rocha-Lona, Jose Arturo GarzaReyes, and Vikas Kumar Building Quality Management Systems: Selecting the Right Methods and Tools explains exactly what directors, practitioners, consultants, and researchers must do to make better choices in the design, implementation, and improvement of their quality management systems (QMSs).

Based on the authors’ decades of industrial experience working on business improvement projects for multinationals looking to design or improve their QMSs, the book discusses building QMSs based on two important organizational elements: needs and resources. It begins with an overview of QMSs and systems thinking and the impact of QMSs on financial performance. Illustrating the process management approach, it reviews the most well-known business and quality improvement models, methods, and tools that support a major QMS. The authors introduce their own time-tested methodology for designing, implementing, and enhancing your own QMS. Highlighting the importance of quality as a way of life, they supply the understanding you’ll need to make the right choices in the development and deployment of your QMS. With a clear focus on business performance and process management, it provides the basis for creating the quality management culture required to become a worldclass organization.

Selected Contents: Introduction. Business Excellence Models. Process Management. Quality Management Systems and Business Processes Diagnostic. Strategic Quality Planning. Building the QMS and Business Improvement Plan by Selecting the Right Models, Methods, and Tools. QMS Implementation. QMS and Business Processes Evaluation. Beyond Quality Management Systems.

Catalog no. K16075, June 2013, 202 pp., Soft Cover ISBN: 978-1-4665-6499-2, $49.95 / £31.99

Mark Graham Brown Manhattan Beach, California, USA

Praise for Previous Editions of this Classic Guide: “Using the Malcolm Baldrige criteria to improve your business makes bottom-line sense. Using Mark Graham Brown’s book to improve your business can compound your results. Mark brings real-world best practices to your desk, making it easier for your company to identify improvement opportunities.”

—Mark A. Naig, Operational Development Specialist, Ericsson, Inc.

The Malcolm Baldrige National Quality Award is the highest level of national recognition for performance excellence that a U.S. organization can receive. An organization must have a role-model organizational management system that ensures continuous improvement in the delivery of products and/or services, demonstrates efficient and effective operations, and provides a way of engaging and responding to stakeholders.

From understanding the scoring system to preparing for a site visit, this book covers all stages in the process. It offers detailed explanations of each examination item and the seven major categories. This edition reflects new criteria, which address education and healthcare.

• Explains the criteria for leadership and the role of senior management in the award process • Illustrates the differences between a long- and short-term strategic plan • Describes how to differentiate and satisfy the requirements for effective process and results • Discusses how to avoid common mistakes when completing the application • Includes rules to use when preparing graphics and chart Catalog no. K14194, August 2013, 408 pp.

Soft Cover ISBN: 978-1-4398-9382-1, $59.95 / £38.99

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Six Sigma

Six Sigma for Powerful Improvement A Green Belt DMAIC Training System with Software Tools and a 25-Lesson Course Charles T. Carroll Six Sigma for Powerful Improvement: A Green Belt DMAIC Training System with Software Tools and a 25-Lesson Course clarifies the long-accepted statistical and logical processes of Six Sigma and provides you with tools you can use again and again in your own projects. Not only does it provide the reasons for using the tools, it reveals the underlying doctrines, formulas, and steps required.

Although the tools and techniques presented are specifically associated with the Define-MeasureAnalyze-Improve-Control (DMAIC) philosophy, they are applicable across a range of management and improvement scenarios. The book starts with an overview, followed by specific techniques and procedures. It presents detailed, illustrated lesson segments that include an agenda, roadmap, objectives, and a list of takeaway concepts.

The Pocket Guide to the Baldrige Award Criteria (5-Pack), 17th Edition Mark Graham Brown Manhattan Beach, California, USA

Updated yearly to match changing requirements, this guide is designed to help you understand the criteria for the Malcolm Baldrige National Quality Award. The Baldrige criteria are being used by thousands of organizations around the world to evaluate their progress toward becoming the best in their fields.

This 17th edition of The Pocket Guide to the Baldrige Criteria begins with commonly asked questions about the award criteria. It then breaks down the 19 items under the seven category headings of the Baldrige criteria with concise explanation and quick tips of what excellent companies do in each area.

Selected Contents: Introduction Questions & Answers

• Provides seven separate Excel tool templates— each with its own user guide and additional smaller tools

The Baldrige Criteria

• Presents completed Excel sample workbooks for each tool to facilitate your comprehension and utilization confidence

Customer Focus

• Includes a CD with a PowerPoint-based DMAIC training course, Excel-based Six Sigma tools and workbooks, and extensive instructor’s notes embedded in each lesson The book uses hundreds of figures and tables to illustrate key concepts and also makes them available in full color on the accompanying CD. This is also true of the figures in the user guides that document the accompanying tools. For each of the tools, the book includes a completed sample workbook. The PowerPoint and Excel lessons and tools are provided in both 2007 and 97-2003 versions.

Leadership Strategic Planning Measurement, Analysis, and Knowledge Management Workforce Focus Process Management Results Additional Reading Catalog no. K21442, June 2013, 64 pp., Soft Cover ISBN: 978-1-4822-0527-5, $39.95 / £25.99

Catalog no. K16064, May 2013, 524 pp.

ISBN: 978-1-4665-6469-5, $99.95 / £63.99

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Six Sigma

Removing the Barriers to Efficient Manufacturing

The Practical Application of the Process Capability Study

Real-World Applications of Lean Productivity

Evolving From Product Control to Process Control

Daniel L. Ferguson

Douglas B. Relyea

This book is a practical roadmap that shows managers how to eliminate the barriers that keep them from achieving high productivity levels while producing consistent quality products. The underlying basis is Deming’s methodology for reducing variability but presents it in a new way by moving from theoretical to real-life application. It also incorporates other common-sense approaches that have proven to be successful and which enhance some specific foundational principles.

Catalog no. K15376, January 2013, 294 pp.

Soft Cover ISBN: 978-1-4665-5551-8, $39.95 / £25.99

Quality Principle Associates, Norwich, Connecticut, USA

Using real-world examples in the context of the shop floor, this book addresses statistical process control through a non-mathematical, step-by-step explanation of the process capability study. It enables manufacturing personnel to understand how to recover a significant return on their investment from statistical process control. Machine operators and supervisors will better understand how they can communicate their process knowledge to management. Managers will then better understand the limitations of the process as it exists and will have a simple tool for managing process improvement.

Catalog no. K12127, January 2011, 163 pp.

Soft Cover ISBN: 978-1-4398-4778-7, $43.95 / £28.99

Your Customers' Perception of Quality

Performance Hubs Engaging Teams in Focused Continuous Improvement

What It Means to Your Bottom Line and How to Control It

Marc Roberts Unipart Expert Practices, The Lean Assessment, North Wales, UK

Baboo Kureemun and Robert Fantina A detailed examination of a new concept in customer centricity, this book explores customer perception of quality and how to measure it. The author introduces a ground-breaking model for quantifying the impact that poor perception of quality has on the bottom line. It helps readers understand the importance of customer perception, how they may be misunderstanding this vital component, and how they can look at data collected from a variety of sources—surveys, customer conversations with sales representatives, etc.—and glean a clear understanding of their customers' perception, and the insight necessary to improve it.

Catalog no. K12047, April 2011, 225 pp.

ISBN: 978-1-4398-4581-3, $55.95 / £35.99

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A must-read for all managers, leaders, and change agents, this book supplies a proven system for engagement that allows teams to use their own data, understand the need for performance improvement, and drive improvements at their own level.

Highlighting common pitfalls in improvement initiatives, it provides the tools to help you avoid the disinterested cultural response to improvement efforts that is all too common in organizations suffering from initiative overload. The book includes a CD project management aids, templates, and slides.

Catalog no. K12832, October 2011, 188 pp.

Soft Cover ISBN: 978-1-4398-6133-2, $43.95 / £28.99

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59

Six Sigma

10 Essentials for High Performance Quality in the 21st Century Diomidis H. Stamatis President, Contemporary Consultants Co., Southgate, Michigan, USA

Identifying ten steps readers can follow to optimize the quality of products and improve customer satisfaction, the book explains the rationale behind each of the steps in separate chapters. It addresses specific quality issues in six different sectors of the economy and provides statistics, tables, and figures from various organizations that support the need for a paradigm shift. The book includes a CD with a wealth of helpful tools—including time management tips, an introduction to International Standards (ISO 9000 and ISO 14000), and a brief summary of the Malcolm Baldrige Award.

Catalog no. K13532, December 2011, 360 pp.

ISBN: 978-1-4398-7600-8, $75.95 / £48.99 Also available as an eBook

What Works for GE May Not Work for You Using Human Systems Dynamics to Build a Culture of Process Improvement Lawrence Solow 3-D Change, Inc., Westampton, New Jersey, USA

Brenda Fake O-2 Optimizing Organizations, San Diego, California, USA

Focusing on Lean Enterprise, Six Sigma, and Human Systems Dynamics, this guide provides new tools for managing and sustaining process improvement in today’s complex non-linear environments and helps readers apply new, relevant theory to their own management practices. With more than 50 combined years of change management and process improvement consulting experience, the authors offer valuable practical insights for creating dynamic organizational change.

They describe the impact of both linear and adaptive approaches to process improvement. Case studies reveal ways to avoid common mistakes and demonstrate how to integrate new processes with past efforts.

A Guide to Lean Six Sigma Management Skills Howard S Gitlow University of Miami, Coral Gables, Florida, USA

Authored by Dr. Howard Gitlow, one of the most respected Six Sigma Master Black Belts, this well-organized volume demonstrates the implementation of quality improvements into all areas of the workplace—from the shop floor through a company’s executive offices. Illustrating his points with a number of case studies, the author provides a compelling argument as to why Six Sigma should be the preferred approach. The book explains how to build an organization that encourages and values the input of quality teams—detailing the steps required to implement and maintain Lean initiatives.

Catalog no. AU416X, June 2009, 166 pp.

ISBN: 978-1-4200-8416-0, $52.95 / £35.99 Also available as an eBook

Corporate Sigma Optimizing the Health of Your Company with Systems Thinking Anwar El-Homsi and Jeff L. Slutsky Proposing that corporations, like humans, have vital systems that must be cared for, this book explains how to use Lean and Six Sigma improvement tools to monitor the vital organs of a corporation. It provides leaders with a roadmap to plot a course from where they are now, to where they want to be. The book describes how to formulate effective organizational vision, mission, and values; how to foster the shared organizational vision to succeed; and how to define strategic business objectives.

Catalog no. K10219, December 2009, 288 pp.

ISBN: 978-1-4398-0394-3, $52.95 / £35.99 Also available as an eBook

Catalog no. K11248, May 2010, 206 pp.

ISBN: 978-1-4398-2599-0, $45.95 / £29.99 Also available as an eBook

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Supply Chain Management

Risk Intelligent Supply Chains

Agribusiness Supply Chain Management

How Leading Turkish Companies Thrive in the Age of Fragility

N. Chandrasekaran Take Solutions, Ltd.,Chennai Tamilnadu, India

G. Raghuram

Çağrı Haksöz Sabancı University, Istanbul, Turkey

“Even though this book is dealing primarily with Turkish industries, it is a must-read for supply chain specialists anywhere in the world.”

—Michael L. Pinedo, Leonard N. Stern School of Business, New York University

“... a pioneering study that clearly elucidates the interrelated issues of risk and supply chains. In this timely and well-written book, Haksöz competently shows how leading Turkish companies manage risk in their supply chains. Çagri Haksöz combines a deep understanding of supply chains and Turkish industry to produce an outstanding book that illuminates both theoretical and implementation questions applicable to a wide cross section of industries and companies worldwide.”

—Ömer S. Benli, Associate Dean, College of Business Administration, California State University, Long Beach

“Through a number of fascinating case studies of some of Turkey’s most successful companies, this book offers important new insights into how to best manage supply chain risk in these times of global uncertainty.”

—Fatih Birol, Ph.D., Chief Economist and Director of Global Energy Economics, International Energy Agency

This book brings the risk intelligent supply chain (RISC) concept to life. It answers the question of how to become a risk intelligent supply chain. It proposes the I-Quartet Model with four essential roles "Integrator, Inquirer, Improviser, and Ingenious," that any supply chain network must play to become risk intelligent. The book also presents never-before-published cases and practices of leading Turkish companies that thrive globally in the age of fragility with their supply chain risk intelligence.

Catalog no. K14526, April 2013, 289 pp.

ISBN: 978-1-4665-0447-9, $79.95 / £49.99 Also available as an eBook

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Indian Institute of Management, Ahmedabad, Gujarat

The agribusiness supply chain includes a number of processes such as supply management, production management, and demand management to customers through a competitive distribution channel.

Each step of the way can be plagued with issues such as diversity of production and demand, bulkiness of produce, perishability, and seasonality. Highlighting the complexity and importance of supply chain management within businesses handling agricultural products, Agribusiness Supply Chain Management addresses issues that help readers systematically approach decision making in the agribusiness sector.

The book covers issues across various spectrums of business and government’s role in the agribusiness supply chain domain. It focuses on actors in supply chains, intrinsic issues that would impact the actors and then the support systems that are essential to make the supply chain achieve its effectiveness. The authors’ clear, well-structured treatment provides a logical approach to key activities of agribusiness supply chain management. They provide numerous case studies that span a wide range of issues and industries that readers can use to sharpen managerial decision making skills.

In today’s world, companies compete on supply chains. With the many factors that can cause delays in deliverability, a well-designed supply chain is a must.

Those who have the capability to establish a distinctive supply chain and create it as a strategic asset are leaders in their business, and in fact emerge as the best in class across industries and markets. This book helps readers develop best practices for making key marketing decisions and designing efficient and effective supply chains that meet global challenges.

Catalog no. K15075, March 2014, 700 pp.

ISBN: 978-1-4665-1674-8, $99.95 / £63.99 Also available as an eBook

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Supply Chain Management

Lean RFS (Repetitive Flexible Supply) Putting the Pieces Together Ian Fraser Glenday and Rick Sather Winner of a Shingo Research and Professional Publication Award!

“This book is the missing link in many Lean journeys.”

—Daniel T. Jones, Chairman, Lean Enterprise Academy UK

Is it possible to be repetitive and flexible—at the same time? Using proven examples and quantifiable evidence, Lean RFS (Repetitive Flexible Supply): Putting the Pieces Together demonstrates that repetitive flexible supply (RfS) is not only possible, but that its implementation can help you reach a new level of improved performance in manufacturing and across your entire supply chain.

Winner of a 2013 Shingo Research and Professional Publication Award, this book is unique in that it clearly spells out the theory and practice originally published in the Shingo Prize winner, Breaking Through to Flow, with actual stories of Kimberly-Clark’s experience in using them over the years with great success. These stories provide a real feel of how this learning-bydoing journey led to "aha!" moments for those involved.

The book also explains why most planning systems in use today will result in a different plan every time, and that these plan changes are actually the cause of the fire fighting that is endemic in most companies.

Supply Chain Optimization through Segmentation and Analytics Gerhard J. Plenert MainStream GS, LLC, Carmichael, California, USA

Supply Chain Segmentation (SCS) has become a critical tool in optimizing supply chain performance. By using segmentation, an organization is taken out of the world of "one size fits all" and brought into a world that facilitates customized responses. This book explains what SCS is, how it works, and the role of analytics. The book gives detailed case studies demonstrating how SCS is applied and improves efficiency. It covers software appropriateness and integration, as well as a full summary perspective on segmentation and its competitive impacts in terms of economic pressure and supplier and consumer interfaces.

• Explains how the analytics process is used to validate the segmentation approach by defining optimal service levels and optimal safety stock, and differentiating between various performance tools like S&OP, OIL, Min/Max, BTO, and more.

• Discusses how to apply segmentation in your organization by answering questions such as what are the IT considerations? How does segmentation work with software products like SAP, Oracle, or Kinaxis?

• Provides an extensive illustrative case study of a company that improved performance by moving away from "one size fits all" to segmentation • Includes detailed examples of how several organizations solved different problems using a segmented planning and scheduling structure

Selected Contents:

Selected Contents:

Twenty-Five Years at Kimberly-Clark. The Fundamentals of Lean/RfS. How It Can Be. The Lean/RfS Corner Pieces. The Lean/RfS Straight Edges.

The Lean/RfS Center Pieces. Putting the Pieces Together.

Segmentation.

Catalog no. K16825, May 2013, 168 pp., Soft Cover ISBN: 978-1-4665-7819-7, $59.95 / £38.99

What is Segmentation and How Does It Work? The Supply Chain. Performance Measures. Analytics and SCS. Segmentation Applied. An Example of SCS – the Analysis Process. An Example of SCS – the Build Process. SCS Execution. SCS in Your Organization.

SCS Key Concepts. Segmentation Effects. Change Management. SCS is Wonderful.

Catalog no. K19057, April 2014, 259 pp.

ISBN: 978-1-4665-8476-1, $69.95 / £44.99 Also available as an eBook

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Supply Chain Management

Capitalizing on Lean Production Systems to Win New Business

Designing Food Safety and Equipment Reliability Through Maintenance Engineering

Creating a Lean and Profitable New Product Portfolio

Sauro Riccetti

Chris Harris and Rick Harris Harris Lean Systems, Murrells Inlet, South Carolina, USA

Although there are many organizations that have implemented Lean production systems and become more profitable as a result, there can be a gap between what those organizations currently do and how they should plan for and profit from new business. Capitalizing on Lean Production Systems to Win New Business: Creating a Lean and Profitable New Product Portfolio explains how to create a Lean product portfolio to fill that gap so you can become more profitable from that new business.

Providing a fundamental understanding of the Lean enterprise production system, this book can help an organization take its current Lean knowledge and translate that knowledge into a step-by-step methodology to win and launch new business. Lean topics covered include: • Value Stream Mapping • Plan for Every Part • Process Design and Standard Work • Scheduling and Material Flow • Machine Changeover • Quality and Continuous Improvement By developing the New Product Acquisition and Launch Portfolio presented in this book, you can dramatically improve your ability to produce the products customers desire and deliver them on time.

Focusing on the concepts that are critical to the longevity of your Lean enterprise system, this book will help you understand how to deliver a product that meets the quality and delivery standards of your customer. It will also help you understand how this new product fits into your Lean enterprise system.

Detailing how to achieve a successful new product launch through upfront planning, this book provides you with the tools to enhance efficiencies throughout your supply chain.

Tetra Pak, Italy

Existing maintenance engineering techniques pursue equipment reliability with a focus on minimal costs, but in the food industry, food safety is the most critical issue. This book identifies how to ensure food product safety through maintenance engineering in a way that produces added value and generates real profits for your organization.

Integrating food safety techniques with reliability and maintenance engineering techniques, Designing Food Safety and Equipment Reliability Through Maintenance Engineering details a maintenance design process that captures all conceivable critical factors in food manufacturing lines. While maintenance engineering normally starts with equipment reliability, this book starts with product safety to identify equipment criticalities and maintenance solutions.

The text examines the problems currently facing the food industry and introduces powerful solutions to help food producers and consultants manage both food safety and manufacturing effectiveness. It presents an innovative tool for weighing food, human, and equipment criticalities and also describes how to maximize maintenance design outcome through the empowerment of equipment operators and their close cooperation with maintenance and quality specialists.

Detailing how to design reliable task lists, the book includes case studies that illustrate the problems that low equipment reliability can create for your customers and your company’s image. It outlines key performance indicators that can help producers and suppliers easily identify quality, availability, and productivity gaps. It also highlights critical factors that can help you avoid process bottlenecks.

Catalog no. K20430, September 2013, 413 pp.

ISBN: 978-1-4665-8987-2, $59.95 / £38.99 Also available as an eBook

Catalog no. K20287, December 2013, 189 pp.

Soft Cover ISBN: 978-1-4665-8633-8, $49.95 / £31.99

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Supply Chain Management

LEAN Supply Chain Planning The New Supply Chain Management Paradigm for Process Industries to Master Today's VUCA World Josef Packowski “To meet our challenging goals we need a systematic and scientific approach for sustainable improvement of our processes. LEAN SCM is developing and providing the roadmap.”

—Thomas Semlinger, Head of Production PCI Europe / BASF Construction Chemicals E-EBE

“If your company lives through a Lean journey, this book will be a helpful compass throughout all the stages of it.”

—David Smith, Executive Vice President of Operations, AstraZeneca

This book introduces a new paradigm and approach to managing variability, uncertainty, and complexity in today’s planning processes and systems. Presenting a supply chain management concept that addresses current problems in the process industry's supply chains, it presents powerful methods developed by leading research institutes, process industry champions, and supply chain experts.

The book explains how readers can change their approach to the fundamental planning paradigms in a manner that will help their organizations achieve higher levels of responsiveness, improved levels of customer service, and increases in cost efficiencies.

Selected Contents: Why LEAN SCM? The Challenge of Supply Chain Planning in VUCA World. Evolution of Supply Chain Management LEAN SCM Paradigm LEAN SCM Perspectives. Strategic LEAN SCM Planning Process.

Tactical SCM Process. Operative LEAN SCM. Organization for LEAN SCM. Performance Management for LEAN SCM. LEAN SCM IT system landscape. LEAN SCM journey. Practioners Experience with LEAN SCM: AstraZeneca’s Lean SCM Journey,. Eli Lilly’s Synchronized Lean Production.

Novartis’ Buffer Management Concept.

AstraZeneca’s Rhythm Wheel Excellence Site. The Lean production Initiative at PCI – a BASF company.

Leveled Flow Design of a Major Scandinavian PharmaCo.

PatientFocused Network Integration in BioPharma Strategic Imperatives for the Years Ahead Robert Handfield North Carolina State University, Raleigh, USA

This book explores patient-focused network integration as quite possibly the only way for organizational evolution to occur. The book discusses how to align enterprises with the patient at the center. It details the historical context of the biopharmaceutical value chain and the current set of challenges facing the industry, and then details the author’s unique and sustainable agenda for change.

The book traces the critical but often ignored relationships between hospitals, insurance companies, biopharma manufacturers, government regulators, and clinical scientists. For too long, these parties have been operating in a void, without recognizing the interconnectedness of their objectives, even though these objectives are often competing and misaligned.

This book points out the gaps that exist and develops a set of recommendations regarding disease treatments, clinical development of new products, and collaboration between these players that can result in a sustainable solution to the healthcare mess.

Each chapter can be viewed as an independent essay, in that it deals with a specific dimension of the healthcare value chain. However, together they provide an integrated discussion on how to begin the task of creating an integrated value chain network for healthcare. The book begins with the patient, and then works its way back down the value chain, all the way to the drug development and clinical trials stage of the value chain. The common thread throughout the chapters is the emphasis on collaboration, strategic alignment, and a focus on delivering value to the end patient.

Catalog no. K15373, June 2013, 200 pp.

ISBN: 978-1-4665-5546-4, $69.95 / £44.99 Also available as an eBook

Catalog no. K21445, November 2013, 493 pp.

ISBN: 978-1-4822-0533-6, $89.95 / £57.99

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Supply Chain Management

Kanban for the Supply Chain

Mastering the Business of Global Trade

Fundamental Practices for Manufacturing Management, Second Edition Stephen Cimorelli Cummins Filtration, Nashville, Tennessee, USA

Following in the footsteps of its popular predecessor, the second edition of this workbook explains how to apply kanban replenishment systems to improve material flow. It provides readers with a detailed roadmap for achieving a successful and sustainable kanban implementation.

Detailing the steps required for each stage of the manufacturing and supply chain management process, this updated edition focuses on creating an environment for success. It addresses internal mechanisms, including leveling production schedules, as well as external elements, such as conducting a thorough analysis of customer demand. Numerous techniques are presented for setting up kanban that consider a wide array of material types, dimensions, and storage media. This edition presents a wealth of new tools and techniques, including: • A statistical data cleansing technique to remove questionable or irrelevant data from kanban calculations • Correlation analysis based on simple Excel techniques to guide the decisions around which part numbers "qualify" for kanban • An alternative "stair-step analysis" approach for those who are unable to generate correlation data and prefer to use more readily available monthly demand history • An approach to analyze supplier performance data vs. lead time and lot size expectations, with risk mitigation strategies for poor performing suppliers Stephen Cimorelli provides actionable advice for installing fundamental kanban concepts that can immediately help you increase manufacturing productivity and profitability. The book includes teambased exercises that reinforce key principles as well as a CD with helpful outlines, charts, figures, and diagrams.

Negotiating Competitive Advantage Contractual Best Practices, Inco Terms, and Leveraging Supply Chain Options Thomas A. Cook American River International, Melville, New York, USA

Much of your company’s success in global trade will be determined by how well you manage contracts and agreements for sale or purchase. Mastering the Business of Global Trade: Negotiating Competitive Advantage Contractual Best Practices, INCO Terms, and Leveraging Supply Chain Options explains the key elements any international business person must know, but more importantly, it also describes how to use negotiation skills, leveraged options, and Inco Terms to extract the maximum benefits from your supply chain.

At the end of the day, landed costs determine pricing and profits. As such, the book clearly explains how landed cost modeling works and how you can use these business models to leverage supply chain options. Illustrating how Inco Terms impact compliance and risk, it details options to help you reduce your exposure to risk as well as best practices to help you steer clear of compliance issues that can cause costly delays.

Managing global supply chains is about constantly striving for efficiency, driving down costs, and increasing profits. With this book, you will not only learn how to negotiate better contracts, but you will also learn how to manage relationships with freight forwarders and customhouse brokers in a manner that will help you get the most value from your service agreements.

The book establishes a very simple, yet comprehensive, roadmap that both the neophyte and the more experienced global supply chain executive can easily follow and master.

Catalog no. K20740, February 2014, 405 pp.

ISBN: 978-1-4665-9578-1, $79.95 / £49.99

Catalog no. K14232, January 2013, 137 pp.

Soft Cover ISBN: 978-1-4398-9549-8, $59.95 / £38.99

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Supply Chain Management

Biopharmaceutical Supply Chains Distribution, Regulatory, Systems and Structural Changes Ahead Robert Handfield North Carolina State University, Raleigh, USA

The global pharmaceutical industry has been subjected to many challenges in the last decade, including more blockbuster drugs reaching the end of their patent life, increased regulation, pricing pressure, channel pressure, counterfeiting, and challenges in clinical trials management. This book covers the major themes and changes in the biopharmaceutical supply chain. It provides an overview of the key challenges and discusses how leading biopharma companies are dealing with these challenges. Bringing together leading researchers and industry executives, it is a mustread for those who want to learn more about achieving success in this industry.

Catalog no. K14356, June 2012, c. 272 pp.

ISBN: 978-1-4398-9970-0, $83.95 / £51.99 Also available as an eBook

Food Safety Regulatory Compliance Catalyst for a Lean and Sustainable Food Supply Chain Preston W. Blevins The global sourcing of ingredients has created complex supply chains, significant management challenges, and additional regulatory compliance requirements. This has placed tremendous pressure on food manufacturers, many of whom lack the knowledge, concepts, techniques, and procedures to comply with these increased requirements. Providing a roadmap for leveraging existing investments in food safety regulatory compliance into superior inventory management, this book explains how to implement Lean operating principles to determine what needs to be improved, in what sequence improvements must be addressed, how one improvement feeds another, and the prerequisites for each improvement.

Catalog no. K12244, November 2012, 342 pp.

ISBN: 978-1-4398-4956-9, $93.95 / £59.99

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Building Network Capabilities in Turbulent Competitive Environments Practices of Global Firms from Korea and Japan Young Won Park University of Tokyo, Japan

Paul Hong University of Toledo, Ohio, USA

Providing an insider’s perspective on strategic and operational practices for company growth, this book examines how Asian global firms and small and medium venture firms have accomplished rapid catch up with leading firms in North America and Europe and established their global competitive advantage. The authors include extensive case studies and reveal the organizational processes of strategy formulation and implementation. Written for those with a basic understanding of business, this book avoids extensive mathematical algorithms and complex theoretical descriptions.

Catalog no. K12308, December 2011, 358 pp.

ISBN: 978-1-4398-5068-8, $87.95 / £55.99

Managing Supply Chains on the Silk Road Strategy, Performance, and Risk Edited by

Çağrı Haksöz, Sridhar Seshadri, and Ananth V. Iyer This book present emerging supply chain practices from the Silk Road regions that include China, Hong Kong, India, Pakistan, Iran, Central Asia, Lebanon, Turkey, Israel, and Hungary. It takes a results-oriented, comparative approach to supply chain management covering structural, strategic, and operational topics.

Providing insights for assessing performance and hedging risk, this is a handbook that no competitive supply chain executive can afford to ignore.

Catalog no. K13018, December 2011, 323 pp.

ISBN: 978-1-4398-6720-4, $75.95 / £48.99 Also available as an eBook

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Supply Chain Management

Internet Retail Operations

Integral Logistics Management

Integrating Theory and Practice for Managers

Operations and Supply Chain Management Within and Across Companies, Fourth Edition

Timothy M. Laseter University of Virginia, Charlottesville, USA

Elliot Rabinovich Arizona State University, Tempe, USA

Paul Schönsleben

The rise of the Internet as the first choice for retail shoppers presents new challenges for retailers and suppliers. This book details how information technology evolved to play such a role in retail supply chain networks, how this has impacted supply chain networks, and how this has changed service operations.

The first part of the text addresses information technology in relation to service and retail industries. The second part covers how the new supply chain dynamics impacts traditional service and retail delivery, the costs involved, the impacts on customer service, and customer expectations. The third part presents case studies of how different retailers meet challenges.

Swiss Federal Institute of Technology, Zurich

The fourth edition of this comprehensive logistics management text covers theoretical and practical aspects of all major operational topics. This new edition contains an expanded chapter on supply chain design. It also includes new sections on: Assessing the economic value of supply chain initiatives, Global trading, Total Cost of Ownership in a global supply chain, Sustainable supply chains, and Supply chain risk management. Summaries, keywords, cases, and exercises are included within chapters. Additional interactive Macromedia Flash elements are made available for download from the book’s companion website.

Catalog no. K10072, July 2011, 268 pp.

ISBN: 978-1-4398-0091-1, $75.95 / £48.99 Also available as an eBook

Catalog no. K13626, August 2011, 1064 pp.

ISBN: 978-1-4398-7823-1, $109.95 / £69.99 Also available as an eBook

Lean Management Principles for Information Technology

Lean Supply Chain Management Essentials A Framework for Materials Managers

Gerhard J. Plenert

Bill Kerber

MainStream GS, LLC, Carmichael, California, USA

Explaining how to introduce Lean principles to IT functions, this book provides the tools and understanding to make better decisions, increase efficiencies, and make IT a major force in delivering sustainable improvements to the supply chain. It introduces powerful Lean tools and techniques and supplies a methodology for implementing them to reduce waste in the IT environment. Discussing information production processes, IT systems, and change management through the lens of Lean principles, the book provides step-by-step guidance for implementing Lean principles in an IT supply chain management system.

Catalog no. AU7860, July 2011, 368 pp.

ISBN: 978-1-4200-7860-2, $87.95 / £55.99

High Mix Lean, Medford, New Jersey, USA

Brian J. Dreckshage Supply Chain Management Consultant, Ballwin, Missouri, USA

This book explains why the traditional materials planning environment, typically embodied by an Enterprise Resource Planning (ERP) system, is an ineffective support system for a company that wants to adopt Lean practices. It offers an alternative methodology for implementing Lean into the supply chain that allows for ongoing experimentation, learning, and improvement. After defining supply chain management and Lean basics, it explores the conflicts between Lean and the traditional framework. It includes a chart that matches Lean tools with the planning and control charts that have served as the model for ERP systems.

Catalog no. K11892, March 2011, 274 pp.

Soft Cover ISBN: 978-1-4398-4082-5, $65.95 / £42.99

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